Composite nonwoven fabric
Patent Information
- Application Number
- CN202522465739.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-20
- Publication Date
- 2026-10-13
- Estimated Expiration
- 2035-11-20
AI Technical Summary
[0004]基于此，有必要针对现有的无纺布产品通用性较差的技术问题，提供一种复合无纺布
[0029]上述的复合无纺布相较于传统的过滤用无纺布产品，通过第一过渡层以及第二过渡层实现从第一功能层到第三功能层的纤维细度、密度、空隙大小的阶梯式梯度变化，从而能够将过滤、吸附、导流、增强以及防护等功能高度集成至一个连续的结构体系中，并确保各个功能区域进行协同工作，以此有效解决了传统层压复合材料的层间剥离问题，带来了更优的力学性能，同时，梯度孔径设计允许小颗粒在致密区域被高效捕获，大颗粒在疏松区域能够快速通过，使得复合无纺布的容尘量更高，气流阻力则更小，进而大大改善复合无纺布的吸附、导湿效率。
Smart Images
Figure CN224847715U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of nonwoven fabric technology, and in particular to a composite nonwoven fabric. Background Technology
[0002] Nonwoven fabric is a sheet-like or fibrous material formed by directly orienting or randomly arranging fibers into a web structure using physical, chemical, or mechanical methods, without traditional textile weaving processes (such as spinning, weaving, and knitting), and then reinforcing it (such as through thermal bonding, chemical bonding, or mechanical entanglement). Its essence is a "fiber aggregate" rather than a "yarn interweaving." Existing nonwoven fabric products possess characteristics such as short process flow, strong structural designability, diverse raw materials, and flexible performance. The production process can be adjusted according to the actual application scenario to obtain nonwoven fabric products with target physical and chemical properties. Compared to traditional textiles, nonwoven fabrics form an irregular fiber network through direct fiber web reinforcement, and can be designed to be isotropic or anisotropic as needed. Currently, nonwoven fabrics are mainly used in medical protection, daily necessities, industrial agriculture, and some high-end manufacturing and products. Specifically, based on the mechanical properties, chemical resistance, and controllable permeability of nonwoven fabrics, they are often used in surgical gowns, masks, filter materials, thermal insulation cloths, lithium battery separators, or composite reinforcing substrates, etc., and their applications are wide-ranging.
[0003] However, existing nonwoven fabric products are usually adjusted according to the specific needs of a particular scenario to obtain targeted products with outstanding single performance, resulting in poor versatility of nonwoven fabric products. Frequent adjustments to the production process can also easily lead to increased production costs and difficulty in controlling yield. Utility Model Content
[0004] Therefore, it is necessary to provide a composite nonwoven fabric to address the technical problem of poor versatility of existing nonwoven products.
[0005] A composite nonwoven fabric includes a first functional layer, a second functional layer, and a third functional layer, which are stacked sequentially.
[0006] The first functional layer is configured as a high-density contact layer with a microporous mesh surface structure; the second functional layer is configured as an adsorption and filtration guiding layer with uniform guiding channels; and the third functional layer is configured as a low-density support layer with a loose macroporous network surface structure.
[0007] The surface of the second functional layer facing the first functional layer is set as the first connecting surface, and the surface of the second functional layer facing the third functional layer is set as the second connecting surface. Based on this, the composite nonwoven fabric also includes a first transition layer and a second transition layer. The first transition layer is disposed on the surface of the first connecting surface, so that the second functional layer is transitionally connected to the first functional layer through the first transition layer. The second transition layer is disposed on the surface of the second connecting surface, so that the second functional layer is transitionally connected to the third functional layer through the second transition layer.
[0008] Compared to the second functional layer, the first transition layer is set as a high-density fine fiber layer, and the second transition layer is set as a low-density coarse fiber layer.
[0009] In one embodiment, the first functional layer described above is configured as either a polypropylene fiber layer or a polylactic acid fiber layer.
[0010] In one embodiment, the fiber fineness of the first functional layer is set to 0.3-1.0 dtex.
[0011] In one embodiment, the average pore size of the first functional layer described above is set to 5-20 μm.
[0012] In one embodiment, the porosity of the first functional layer is set to 80%-90%.
[0013] In one embodiment, the second functional layer described above is configured as either a bicomponent fiber layer or a low-melting-point fiber layer.
[0014] In one embodiment, the fiber fineness of the second functional layer is set to 1.0-2.5 dtex.
[0015] In one embodiment, the porosity of the second functional layer is set to 75%-85%.
[0016] In one embodiment, the aforementioned third functional layer is configured as a high-strength, high-modulus fiber layer.
[0017] In one embodiment, the aforementioned third functional layer may incorporate one of coarse denier PET spunbond, PET / PET bicomponent spunbond, aramid, or carbon fiber short fibers.
[0018] In one embodiment, the fiber fineness of the aforementioned third functional layer is set to 2.2-6.0 dtex.
[0019] In one embodiment, the porosity of the aforementioned third functional layer is set to 85%-95%.
[0020] In one embodiment, the average pore size of the third functional layer is set to 50-200 μm.
[0021] In one embodiment, the first transition layer described above is configured as a high-adsorption-performance layer.
[0022] In one embodiment, the first transition layer described above may be incorporated into either activated carbon powder or zeolite molecular sieve microspheres.
[0023] In one embodiment, the fiber fineness of the first transition layer is set to 0.5-1.5 dtex.
[0024] In one embodiment, the porosity of the first transition layer is set to 70%-80%.
[0025] In one embodiment, the second transition layer described above is configured as a reinforcing fiber layer.
[0026] In one embodiment, the second transition layer described above may be incorporated into either polyester PET staple fiber or chopped glass fiber.
[0027] In one embodiment, the fiber fineness of the second transition layer is set to 1.5-3.0 dtex.
[0028] In one embodiment, the porosity of the second transition layer is set to 80%-90%.
[0029] Compared to traditional filter nonwoven fabrics, the aforementioned composite nonwoven fabric achieves a stepwise gradient change in fiber fineness, density, and pore size from the first functional layer to the third functional layer through the first and second transition layers. This allows for the high integration of filtration, adsorption, flow guidance, reinforcement, and protection functions into a continuous structural system, ensuring that each functional area works collaboratively. This effectively solves the interlayer delamination problem of traditional laminated composite materials, resulting in superior mechanical properties. At the same time, the gradient pore size design allows small particles to be efficiently captured in dense areas and large particles to pass through quickly in loose areas, resulting in higher dust holding capacity and lower airflow resistance, thereby greatly improving the adsorption and moisture wicking efficiency of the composite nonwoven fabric. Attached Figure Description
[0030] Figure 1 This is a schematic diagram of the structure of the composite nonwoven fabric in one embodiment. Detailed Implementation
[0031] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.
[0032] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.
[0033] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.
[0034] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0035] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.
[0036] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.
[0037] Please see Figure 1This utility model discloses a composite nonwoven fabric 1, which includes a first functional layer 10, a second functional layer 20, and a third functional layer 30, which are sequentially stacked. The first functional layer 10 is a high-density contact layer with a microporous mesh surface structure to provide a comfortable feel, block large-diameter solid particles and droplets, and guide liquids and vapors to the second functional layer 20, thereby ensuring the air permeability of the nonwoven fabric. The second functional layer 20 is an adsorption and filtration guiding layer with uniform flow channels to achieve the adsorption, filtration, and flow guiding functions of the nonwoven fabric. The third functional layer 30 is a low-density support layer with a loose, large-pore network surface structure, providing support for the first functional layer 10 and the second functional layer 20 while ensuring the final air permeability channels, thus protecting the core layer, i.e., the second functional layer 20. To further enhance the adsorption, filtration, and flow guiding functions of the second functional layer 20, the surface of the second functional layer 20 facing the first functional layer 10 is set as the first connecting surface, and the surface of the second functional layer 20 facing the third functional layer 30 is set as the second connecting surface. Based on this, the composite nonwoven fabric 1 also includes a first transition layer 40 and a second transition layer 50. The first transition layer 40 is disposed on the surface of the first connecting surface, so that the second functional layer 20 is transitionally connected to the first functional layer 10 through the first transition layer 40. The second transition layer 50 is disposed on the surface of the second connecting surface, so that the second functional layer 20 is transitionally connected to the third functional layer 30 through the second transition layer 50. More specifically, relative to the second functional layer 20, the first transition layer 40 is set as a high-density fine fiber layer, and the second transition layer 50 is set as a low-density coarse fiber layer; thus, the first transition layer 40 can specifically enhance the adsorption of the second functional layer 20, and at the same time form a density gradient with the first functional layer 10 and the second functional layer 20; while the second transition layer 50 can specifically enhance the air permeability and mechanical strength of the second functional layer 20, and at the same time form a density gradient with the second functional layer 20 and the third functional layer 30. Based on the above configuration, compared with traditional nonwoven filter products, the composite nonwoven fabric 1 of this invention achieves a stepwise gradient change in fiber fineness, density, and pore size from the first functional layer 10 to the third functional layer 30 through the first transition layer 40 and the second transition layer 50. This allows for the high integration of functions such as filtration, adsorption, flow guidance, reinforcement, and protection into a continuous structural system, ensuring that each functional area works collaboratively. This effectively solves the interlayer delamination problem of traditional laminated composite materials, resulting in superior mechanical properties. At the same time, the gradient pore size design allows small particles to be efficiently captured in dense areas and large particles to pass through quickly in loose areas, resulting in higher dust holding capacity and lower airflow resistance for the composite nonwoven fabric 1, thereby greatly improving the adsorption and moisture-wicking efficiency of the composite nonwoven fabric 1.
[0038] Furthermore, in one embodiment, the first functional layer 10 is configured as either a polypropylene fiber layer or a polylactic acid fiber layer; in one embodiment, the fiber fineness of the first functional layer 10 is set to 0.3-1.0 dtex; in one embodiment, the average pore size of the first functional layer 10 is set to 5-20 μm; in one embodiment, the porosity of the first functional layer 10 is set to 80%-90%. The first functional layer 10, based on its ultrafine fiber fineness, can provide a superior tactile feel and reduce frictional irritation. Simultaneously, the small pore size can improve the retention rate of the first functional layer 10 for large particles.
[0039] Furthermore, in one embodiment, the second functional layer 20 is configured as either a bicomponent fiber layer or a low-melting-point fiber layer; in one embodiment, the fiber fineness of the second functional layer 20 is set to 1.0-2.5 dtex; in one embodiment, the porosity of the second functional layer 20 is set to 75%-85%. Compared to the first functional layer 10, the second functional layer 20, based on coarser fibers, can ensure stronger air permeability and moisture permeability, while achieving better flow guidance and filtration performance.
[0040] Furthermore, in one embodiment, the third functional layer 30 is configured as a high-strength, high-modulus fiber layer. Specifically, the third functional layer 30 may incorporate one of coarse denier PET spunbond, PET / PET bicomponent spunbond, aramid, or carbon fiber short fibers. In one embodiment, the fiber fineness of the third functional layer 30 is set to 2.2-6.0 dtex. In one embodiment, the porosity of the third functional layer 30 is set to 85%-95%. In one embodiment, the average pore size of the third functional layer 30 is set to 50-200 μm. Based on the large-pore structure layer composed of coarse fibers, the third functional layer 30 can provide high-strength support for the composite nonwoven fabric 1. At the same time, the high porosity ensures a high airflow rate for the third functional layer 30, forming an ultra-permeable structure.
[0041] Furthermore, in one embodiment, the first transition layer 40 is configured as a high-adsorption-performance layer. Specifically, the first transition layer 40 may be incorporated with either activated carbon powder or zeolite molecular sieve microspheres. In one embodiment, the fiber fineness of the first transition layer 40 is set to 0.5-1.5 dtex. In another embodiment, the porosity of the first transition layer 40 is set to 70%-80%. The fiber fineness of the first transition layer 40 is between that of the second functional layer 20 and the first functional layer 10, thereby achieving a gradient transition in fiber fineness between the first functional layer 10 and the second functional layer 20. Based on its high adsorption performance, it can ensure efficient capture of particles to achieve efficient filtration while facilitating the guidance of target components to the second functional layer 20.
[0042] Furthermore, in one embodiment, the second transition layer 50 is configured as a reinforcing fiber layer. Specifically, the second transition layer 50 may incorporate either polyester PET short fibers or chopped glass fibers. In one embodiment, the fiber fineness of the second transition layer 50 is set to 1.5-3.0 dtex. In another embodiment, the porosity of the second transition layer 50 is set to 80%-90%. The fiber fineness of the second transition layer 50 is between that of the second functional layer 20 and the third functional layer 30, thereby achieving a gradient transition in fiber fineness between the third functional layer 30 and the second functional layer 20. Based on the mechanical properties of its reinforcing fibers, it synergistically strengthens the puncture resistance of the composite nonwoven fabric 1 with the third functional layer 30 while ensuring low airflow resistance.
[0043] In summary, compared with traditional filter nonwoven products, the composite nonwoven fabric disclosed in this utility model achieves a stepwise gradient change in fiber fineness, density, and pore size from the first functional layer to the third functional layer through the first and second transition layers. This allows for the high integration of functions such as filtration, adsorption, flow guidance, reinforcement, and protection into a continuous structural system, ensuring that each functional area works synergistically. This effectively solves the interlayer delamination problem of traditional laminated composite materials, resulting in superior mechanical properties. At the same time, the gradient pore size design allows small particles to be efficiently captured in dense areas and large particles to pass through quickly in loose areas, resulting in higher dust holding capacity and lower airflow resistance of the composite nonwoven fabric, thereby greatly improving the adsorption and moisture wicking efficiency of the composite nonwoven fabric.
[0044] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0045] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.
Claims
1. A composite nonwoven fabric, characterized in that, include: The first functional layer, the second functional layer, and the third functional layer are stacked sequentially. The first functional layer is a high-density contact layer with a microporous mesh surface structure; the second functional layer is an adsorption and filtration flow guiding layer with uniform flow guiding channels; and the third functional layer is a low-density support layer with a loose macroporous network surface structure. The surface of the second functional layer facing the first functional layer is set as the first connecting surface, and the surface of the second functional layer facing the third functional layer is set as the second connecting surface; based on this, the composite nonwoven fabric also includes a first transition layer and a second transition layer, the first transition layer is disposed on the surface of the first connecting surface, and the second transition layer is disposed on the surface of the second connecting surface.
2. The composite nonwoven fabric according to claim 1, characterized in that, Compared to the second functional layer, the first transition layer is set as a high-density fine fiber layer, and the second transition layer is set as a low-density coarse fiber layer.
3. The composite nonwoven fabric according to claim 1, characterized in that, The fiber fineness of the first functional layer is set to 0.3-1.0 dtex.
4. The composite nonwoven fabric according to claim 1, characterized in that, The average pore size of the first functional layer is set to 5-20 μm.
5. The composite nonwoven fabric according to claim 1, characterized in that, The porosity of the first functional layer is set to 80%-90%.
6. The composite nonwoven fabric according to claim 1, characterized in that, The fiber fineness of the second functional layer is set to 1.0-2.5 dtex.
7. The composite nonwoven fabric according to claim 1, characterized in that, The porosity of the second functional layer is set to 75%-85%.
8. The composite nonwoven fabric according to claim 1, characterized in that, The fiber fineness of the third functional layer is set to 2.2-6.0 dtex.
9. The composite nonwoven fabric according to claim 1, characterized in that, The porosity of the third functional layer is set to 85%-95%.
10. The composite nonwoven fabric according to claim 1, characterized in that, The average pore size of the third functional layer is set to 50-200 μm.