CN118531563A - Quality control method for needled non-woven fabric - Google Patents
Quality control method for needled non-woven fabric Download PDFInfo
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Abstract
The application relates to a quality control method of needled non-woven fabrics, wherein the method comprises the steps of sequentially carrying out pretreatment, main needling and cloth cover needling on a fiber web to obtain initial cloth, wherein the pretreatment and the main needling are used for adjusting the fiber web structure, and the cloth cover needling is used for adjusting the surface density and thickness of the fiber web; heating the initial cloth in the closed space by using circulating air, and drying the initial cloth by controlling the temperature of a drying oven in an upper area and a lower area of the cloth, wherein the drying is used for adjusting the hardness degree of the cloth; carrying out surface treatment on the dried cloth by a hot roller, wherein the surface treatment is used for adjusting the surface smoothness of the cloth; and carrying out product quality detection on the cloth subjected to surface treatment, and carrying out relevant adjustment on the cloth which does not meet the product quality standard to obtain the cloth which meets the product quality standard, wherein the product quality detection comprises detection of the thickness, the strength and the elongation of the cloth, the gram weight, the softness and hardness degree of the cloth, the surface smoothness degree of the cloth and the metal residual rate. The quality control of the existing needled non-woven fabric is realized, the quality of the non-woven fabric is effectively improved, and the problem of low quality of the existing needled non-woven fabric in the related art is solved.
Description
Technical Field
The application relates to the technical field of non-woven fabric production, in particular to a quality control method of needled non-woven fabric.
Background
The needled non-woven fabric is one of dry non-woven fabrics, and is a non-woven fabric process for reinforcing a fiber web by repeatedly puncturing the fiber by using needles after opening, carding and lapping. In recent years, the needled non-woven fabric industry is in a high-speed growth period, the foreign advanced non-woven fabric technology is gradually absorbed and digested, the domestic needled non-woven fabric technology is rapidly promoted, various new technologies are sequentially developed, the successful combination of various equipment technologies and process technologies is achieved, bottlenecks for limiting productivity, varieties and energy consumption are opened, the application field of products is greatly widened, and the upgrading of the whole industry is promoted.
At present, although the quality control process of the needled non-woven fabric is gradually perfected, the quality control process is not in place, so that the existing needled non-woven fabric has the problem of low quality.
Disclosure of Invention
The embodiment of the application provides a quality control method of a needled non-woven fabric, which at least solves the problem of low quality of the existing needled non-woven fabric in the related technology.
In a first aspect, an embodiment of the present application provides a quality control method for a needled nonwoven fabric, where the method includes:
The method comprises the steps of sequentially carrying out pre-needling treatment, main needling treatment and cloth cover needling treatment on a fiber net to obtain initial cloth, wherein the pre-needling treatment is used for adjusting the fiber net structure, and the cloth cover needling treatment is used for adjusting the surface density and thickness of the fiber net;
Heating the initial cloth in the closed space by using circulating air, and drying the initial cloth by controlling the temperature of an oven in the upper area and the lower area of the cloth, wherein the drying is used for adjusting the hardness degree of the cloth;
carrying out surface treatment on the dried cloth by a hot roller, wherein the surface treatment is used for adjusting the surface smoothness of the cloth;
And carrying out product quality detection on the cloth subjected to surface treatment, and carrying out relevant adjustment on the cloth which does not meet the product quality standard to obtain the cloth which meets the product quality standard, wherein the product quality detection comprises detection of the thickness, the strength and the elongation of the cloth, the gram weight, the softness and hardness degree of the cloth, the surface smoothness degree of the cloth and the metal residual rate.
In an embodiment, performing related adjustment on a cloth which does not meet a product quality standard to obtain a cloth which meets the product quality standard, including:
adjusting needling depths and needling densities of the pre-needling treatment, the main needling treatment and the cloth cover needling treatment under the condition that the thickness, the strength and the elongation of the cloth do not meet quality standards;
Adjusting the temperature of an oven in the upper area and the lower area of the cloth under the condition that the hardness degree of the cloth does not accord with the quality standard;
under the condition that the surface smoothness of the cloth does not accord with the quality standard, adjusting the parameters of the surface treatment of the hot roller;
And filtering the metal in the cloth under the condition that the metal residual rate of the cloth does not accord with the quality standard, and detecting the metal residual of each device.
In one embodiment, the needling depth of the pre-needling treatment is 3.0-12.5mm and the needling density of the pre-needling treatment is 40-70 l per square meter;
The needling depth of the main needling treatment is 2.5-8.0mm, and the needling density of the main needling treatment is 120-200 l per square meter;
The needling depth of the needling treatment of the cloth cover is 2.0-7.0mm, and the needling density of the needling treatment of the cloth cover is 140-190 l per square meter.
In an embodiment, the heating in the closed space by using circulated air and drying the initial cloth by controlling the temperature of the oven in the upper area and the lower area of the cloth comprises:
And heating in the closed space by using fuel gas, and respectively controlling the oven temperatures of the upper area and the lower area of the cloth by using circulating air, wherein the oven temperatures of the upper area and the lower area of the cloth are controlled according to the characteristics of the cloth, the oven temperature of the upper area of the cloth is 0-220 ℃, and the oven temperature of the lower area of the cloth is 0-220 ℃.
In one embodiment, the surface treatment is performed on the dried cloth by a hot roller, and the surface treatment is used for adjusting the surface smoothness of the cloth, and comprises the following steps:
the oil in the two hot rolls is circularly heated by utilizing electric energy, the temperatures of the two hot rolls are respectively controlled, and roll treatment is carried out on the upper surface and the lower surface of the cloth, wherein the temperature of an upper roll in the hot rolls is 0-300 ℃, the temperature of a lower roll in the hot rolls is 0-300 ℃, and the speed of the hot rolls is 3-10 m/min.
In an embodiment, before the product quality inspection of the surface-treated cloth, the method further comprises:
And uniformly powdering the surface of the cloth by a powdering machine.
In one embodiment, before subjecting the web to the pre-needling treatment, the main needling treatment, and the cloth cover needling treatment in that order to obtain the initial cloth, the method further comprises:
Different kinds of fibers are put into different bale openers according to the production formula, and the proportion of the input materials is controlled;
Carrying out metal detection on different kinds of fibers passing through an unpacking machine, and carrying out initial mixing and opening on detected raw materials through a mixing large bin;
further mixing and finely opening the fibers mixed by the big bin;
and sucking the mixed and opened fibers into a cotton storage box through a fan for storage and standby.
And (3) conveying the fibers of the cotton storage box to a pneumatic cotton box through a powerful fan, and accurately weighing the fibers through a belt scale.
In one embodiment, after the fibers of the hopper are fed to the pneumatic hopper by a powerful fan and precisely weighed by a belt scale, the method further comprises:
And carding the weighed different fibers into a single-layer fiber web which is arranged in a crossing way and uniformly mixed by a carding machine.
In one embodiment, when the weighed different fibers are carded into a cross-aligned, uniformly mixed single layer web by a carding machine, comprising:
The single-layer fiber web is paved into a multi-layer fiber web with a preset layer number and uniform thickness through a lapping machine, and the multi-layer fiber web is lapped.
In one embodiment, after the single-layer web is laid by a lapping machine into a multi-layer web of a predetermined number of layers and uniform thickness, the multi-layer web is lapped, the method further comprises:
The fiber arrangement mode is changed through a drawing machine, and the fiber web is arranged differently.
The quality control method for the needled non-woven fabric provided by the embodiment of the application has at least the following technical effects.
The method comprises the steps of sequentially carrying out pre-needling treatment, main needling treatment and cloth cover needling treatment on a fiber net to obtain initial cloth, wherein the pre-needling treatment and the main needling treatment are used for adjusting the fiber net structure, and the cloth cover needling treatment is used for adjusting the surface density and thickness of the fiber net; heating the initial cloth in the closed space by using circulating air, and drying the initial cloth by controlling the temperature of a drying oven in an upper area and a lower area of the cloth, wherein the drying is used for adjusting the hardness degree of the cloth; carrying out surface treatment on the dried cloth by a hot roller, wherein the surface treatment is used for adjusting the surface smoothness of the cloth; and carrying out product quality detection on the cloth subjected to surface treatment, and carrying out relevant adjustment on the cloth which does not meet the product quality standard to obtain the cloth which meets the product quality standard, wherein the product quality detection comprises detection of the thickness, the strength and the elongation, the gram weight, the softness and hardness degree of the cloth, the surface smoothness degree of the cloth and the metal residual rate of the cloth, so that the quality control of the existing needled non-woven fabric is realized, the quality of the non-woven fabric is effectively improved, and the problem of low quality of the existing needled non-woven fabric in the relevant technology is solved.
The details of one or more embodiments of the application are set forth in the accompanying drawings and the description below to provide a more thorough understanding of the other features, objects, and advantages of the application.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute a limitation on the application. In the drawings:
FIG. 1 is a flow chart of a quality control of a needled nonwoven;
fig. 2 is a flowchart illustrating step S109-step S111 and step S113 according to an exemplary embodiment;
Fig. 3 is a flowchart illustrating steps S101-S105 according to an exemplary embodiment.
Detailed Description
The present application will be described and illustrated with reference to the accompanying drawings and examples in order to make the objects, technical solutions and advantages of the present application more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the application. All other embodiments, which can be made by a person of ordinary skill in the art based on the embodiments provided by the present application without making any inventive effort, are intended to fall within the scope of the present application.
It is apparent that the drawings in the following description are only some examples or embodiments of the present application, and it is possible for those of ordinary skill in the art to apply the present application to other similar situations according to these drawings without inventive effort. Moreover, it should be appreciated that while such a development effort might be complex and lengthy, it would nevertheless be a routine undertaking of design, fabrication, or manufacture for those of ordinary skill having the benefit of this disclosure, and thus should not be construed as having the benefit of this disclosure.
Reference in the specification to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the application. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. It is to be expressly and implicitly understood by those of ordinary skill in the art that the described embodiments of the application can be combined with other embodiments without conflict.
Unless defined otherwise, technical or scientific terms used herein should be given the ordinary meaning as understood by one of ordinary skill in the art to which this application belongs. The terms "a," "an," "the," and similar referents in the context of the application are not to be construed as limiting the quantity, but rather as singular or plural. The terms "comprising," "including," "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, article, or apparatus that comprises a list of steps or modules (elements) is not limited to only those steps or elements but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus. The terms "connected," "coupled," and the like in connection with the present application are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. The term "plurality" as used herein means two or more. "and/or" describes an association relationship of an association object, meaning that there may be three relationships, e.g., "a and/or B" may mean: a exists alone, A and B exist together, and B exists alone. The character "/" generally indicates that the context-dependent object is an "or" relationship. The terms "first," "second," "third," and the like, as used herein, are merely distinguishing between similar objects and not representing a particular ordering of objects.
At present, the production process flow of the needled non-woven fabric mainly comprises the following steps: ① Preparing raw materials. Chemical fibers such as polyester and polypropylene are generally used as raw materials. ② Carding and combing. The fibrous material is carded to remove impurities and form a continuous web. ③ pre-needling. The web is initially consolidated by a needling process. ④ main needling. Further reinforcing the fiber net through a needling process to form a preliminary non-woven fabric structure. ⑤ heat setting. The nonwoven fabric is heat-treated to fix its structure and to improve strength. ⑥ And (5) surface treatment. The surface of the nonwoven fabric is sometimes subjected to singeing and chemical oiling to increase its smoothness and breathability. ⑦ are wound. After checking, the non-woven fabric is coiled and packaged. The needled non-woven fabric is widely applied and mainly applied to: 1A, medical and health field: a face material for a diaper or a sanitary napkin; surgical gowns, caps, shoe covers, masks, face masks, hospital patients, hospital bed sheets, mattress pads, pillowcases and antibacterial curtains; wet towel, cotton ball, disinfection wrapping cloth; white blood cell separation material, artificial skin; the basic material of labor protection clothing is used in the places with radiation; medical adhesive cloth base cloth, bandage base cloth, wound compress, wound cushion and blood sucking cloth. 2, household decoration field: carpeting and flooring materials; a carpet backing; curtains and curtains; tablecloth, bedspread and wall-mounted cloth; cloth for coating mattress and furniture; an artificial lawn. 3, clothing field: various garment trim liners; winter dress thermal insulation flocculus; outer garments and inner garments; auxiliary materials for clothes (clothing labels, laces, bra protection, shoulder pads, etc.). 4, footwear and leather-like fields: lining of fabric, artificial deer skin, shoes, leather bags and leather shoes; intermediate liners and support (reinforcement) materials. 5. Filtration material: conventional filtration: used for air conditioning, kitchen fume filter, beverage liquid filter, etc. 6. High temperature resistant and corrosion resistant filter material: the filter is used for filtering high-temperature and corrosive tail gas and dust discharged by an industrial kiln. 7. Geotextile: geotextile infiltration ditches for underground drainage and irrigation; geotextile for separating and reinforcing in road and railway construction; reinforcing geotextile for bank slope dykes and dams; geotextile for bridge engineering; the waste is deposited late; impermeable geotextile for an artificial pond; waterproof asphalt base fabric. 8. The automotive industry: seat covers, sun visors, door soft gaskets, roof and luggage compartment gaskets and covering materials, thermal and acoustic insulation materials, carburettors, air filtration cotton, tufted carpet backings, needled loop compression molded carpets, sofa upholstery materials. 9. Industry: oil absorption materials for recovering oil leakage in oil extraction areas on the sea surface of a harbor; An electronically insulating material; a battery separator cloth; industrial polishing materials; glass fiber reinforced plastic tube reinforced base material, industrial adhesive tape base material and industrial hose base material. 10. And (3) agriculture: household harvest cloth, frost prevention curtain, insect prevention cloth, soil moisture preservation cloth, seedling raising cloth and greenhouse. 11. Household articles: the novel multifunctional clothes cleaner comprises a wiping cloth, a shoe wiping cloth, a western-style clothes sleeve, a burden cloth, a bedding collection bag, a pillowcase, a seat sand sleeve, a gift bag, a tea bag, a kitchen tea filter and a water filter bag. 12. Other: a disk liner; coating a base fabric; packaging materials, and the like.
At present, although the quality control process of the needled non-woven fabric is gradually perfected, the quality control process is not in place, so that the existing needled non-woven fabric has the problem of low quality.
Therefore, the embodiment of the application provides a quality control method of a needled non-woven fabric, so as to solve the problems.
The embodiment of the application provides a quality control method for a needled non-woven fabric, fig. 1 is a flow chart of quality control for the needled non-woven fabric, fig. 2 is a flow chart of steps S109-S111 and S113 shown in an exemplary embodiment, and as shown in fig. 1 and 2, the quality control method for the needled non-woven fabric comprises:
Step 109, the fiber net is subjected to pre-needling treatment, main needling treatment and cloth cover needling treatment in sequence to obtain initial cloth, wherein the pre-needling treatment and the main needling treatment are used for adjusting the fiber net structure, and the cloth cover needling treatment is used for adjusting the surface density and the thickness of the fiber net.
And S110, heating the initial cloth in the closed space by using circulating air, and drying the initial cloth by controlling the temperature of the oven in the upper area and the lower area of the cloth, wherein the drying is used for adjusting the hardness degree of the cloth.
And step S111, carrying out surface treatment on the dried cloth by a hot roller, wherein the surface treatment is used for adjusting the surface smoothness of the cloth.
And S113, carrying out product quality detection on the cloth subjected to surface treatment, and carrying out relevant adjustment on the cloth which does not meet the product quality standard to obtain the cloth which meets the product quality standard, wherein the product quality detection comprises detection of the thickness, the strength and the elongation of the cloth, the gram weight, the softness and hardness degree of the cloth, the surface smoothness degree of the cloth and the metal residual rate.
In summary, according to the quality control method for the needled non-woven fabric provided by the embodiment of the application, the fiber web is sequentially subjected to the pre-needling treatment, the main needling treatment and the cloth cover needling treatment to obtain initial cloth, wherein the pre-needling treatment and the main needling treatment are used for adjusting the fiber web structure, and the cloth cover needling treatment is used for adjusting the surface density and the thickness of the fiber web; heating the initial cloth in the closed space by using circulating air, and drying the initial cloth by controlling the temperature of a drying oven in an upper area and a lower area of the cloth, wherein the drying is used for adjusting the hardness degree of the cloth; carrying out surface treatment on the dried cloth by a hot roller, wherein the surface treatment is used for adjusting the surface smoothness of the cloth; and carrying out product quality detection on the cloth subjected to surface treatment, and carrying out relevant adjustment on the cloth which does not meet the product quality standard to obtain the cloth which meets the product quality standard, wherein the product quality detection comprises detection of the thickness, the strength and the elongation of the cloth, the gram weight, the softness and hardness degree of the cloth, the surface smoothness degree of the cloth and the metal residual rate. The quality control of the existing needled non-woven fabric is realized, the quality of the non-woven fabric is effectively improved, and the problem of low quality of the existing needled non-woven fabric in the related art is solved.
Fig. 3 is a flowchart illustrating step S101-step S105 according to an exemplary embodiment, and as shown in fig. 3, before the web is sequentially subjected to the pre-needling process, the main needling process, and the cloth cover needling process, the method further includes:
Step S101, putting different kinds of fibers into different bale openers according to production formulas, and controlling the proportion of materials put into the bale openers.
Optionally, different fibers (e.g., cotton, polyester, nylon, etc.) are mixed in precise proportions to achieve specific performance requirements such as strength, absorbency, softness, etc. For example, the addition of a proportion of polyester fibers can increase the wear resistance and elasticity of the cloth, while cotton fibers can increase comfort and moisture and air permeability. The proportion is controlled through the bale opener, so that the accurate throwing of raw materials can be realized, and the consistency of the quality of subsequent products is ensured.
And S102, detecting metals of different types of fibers passing through the bale opener, and carrying out initial mixing and opening on the detected raw materials through a mixing large bin.
Optionally, metal detection is an important step in ensuring safe production, and can prevent metal foreign matters from mixing in the production process, damaging equipment or affecting product quality. Once the metal impurities are detected, measures are taken to remove immediately, ensuring the purity of the fibers. And then, through the mixing and opening processes of the large mixing bin, different fibers are fully contacted and uniformly mixed, and meanwhile, fiber blocks are opened, so that the uniformity and the efficiency of subsequent processing are improved.
And step S103, further mixing and finely opening the fibers mixed by the large bin.
Optionally, the mixing uniformity and the opening degree of the fibers are further enhanced, the fibers are fully interwoven, and the fluffiness of the fiber layer and the uniformity of subsequent net forming are improved. This step helps to improve the uniformity and overall strength of the nonwoven while also providing good fiber condition for the subsequent forming process.
And step S104, sucking the mixed and opened fibers into a cotton storage box through a fan for storage for later use.
Optionally, the negative pressure effect of the fan is utilized to convey the fibers into the cotton storage box, so that the labor intensity of manual conveying is reduced, and the production efficiency is improved. The cotton storage box plays a role in temporary storage, fiber raw materials are conveniently supplied timely according to production requirements, and continuity of production flow is guaranteed. Simultaneously, the cotton storage box can isolate external pollution to a certain extent, and keep the fiber clean.
And step 105, conveying the fibers of the cotton storage box to a pneumatic cotton box through a powerful fan, and accurately weighing the fibers through a belt scale.
Optionally, the fibers of the cotton storage box are sent to the pneumatic cotton box through two powerful fans, and the fibers are accurately weighed through the belt scale, so that the gram weight full width uniformity of the product is ensured. In particular, the powerful fans ensure the continuity and speed of fiber transmission, and the pneumatic cotton box uses the air pressure to maintain the loose state of the fibers, thereby creating good conditions for the next processing (such as carding and web forming). The use of a belt scale enables accurate metering of the weight of the fibre, which is critical to controlling the weight of the finished product, the cost and ensuring the accuracy of the formulation. Accurate weighing is beneficial to standardized production, raw material waste is reduced, and stability of product quality is ensured.
The steps S101-S105 form a fiber pretreatment flow, so that the product quality is ensured, the production efficiency and the economic benefit are improved, and a solid foundation is laid for the subsequent non-woven fabric manufacture.
In one embodiment, after the fibers of the cotton storage tank are sent to the pneumatic cotton tank by the powerful fan and precisely weighed by the belt scale in step S105, the method further includes:
step S106, carding the weighed different fibers into a single-layer fiber web which is arranged in a crossing way and uniformly mixed by a carding machine.
Alternatively, the carding machine cardes, mixes and crossly arranges the fed fibers by the coordinated movement of a series of carding elements, such as a carding roll, a fixed needle plate and a movable needle plate. The process can effectively open the fiber bundles, remove impurities and caking in the fibers, and enable the fibers to be loose and uniform. The fibers are transferred and carded for multiple times in the carding process, so that the full mixing among the fibers and the crossing of the fiber arrangement are realized, which is beneficial to improving the uniformity of subsequent web formation and the binding force among the fibers. The staggered arrangement of the fibers increases the physical bond points, and thus improves the stability and strength of the web.
In one embodiment, at step S106, carding the weighed different fibers into a cross-aligned, uniformly mixed single layer web by a carding machine, comprising:
Step S107, paving the single-layer fiber net into a multi-layer fiber net with preset layer number and uniform thickness through a lapping machine, and lapping the multi-layer fiber net.
Alternatively, the lapping machine stacks the single layer webs according to preset layer number and thickness requirements by precisely controlling the delivery and distribution of the fibers. Lapping refers to the application of a suitable overlapping treatment to the edges of the multi-layer web to ensure that the layers of fibers are firmly bonded together during subsequent processing (e.g., needling, hot melt, etc.) to prevent delamination or misalignment.
In one embodiment, the different weighed fibers are carded into a cross-aligned, uniformly mixed single layer web by a carding machine at step S107, comprising:
step S108, changing the arrangement mode of the fibers through a drawing machine, and arranging the fiber webs differently.
Optionally, the drafting machine alters the arrangement and density distribution of the fibers in the web by stretching. This process may be uniaxial stretching or may be a bi-axial balanced or unbalanced stretching, depending on the performance requirements of the desired product. During the stretching process, the interaction forces between the fibers are readjusted and the fibers may be further straightened, oriented or redistributed, thereby affecting the physical and mechanical properties of the web. The dimensional stability, strength and elongation of the fiber web are improved, and the strength, air permeability and other properties of the product can be directionally optimized by directionally arranging the fibers.
In one embodiment, in step S109, the web is sequentially subjected to a pre-needling process, a main needling process, and a cloth cover needling process, so as to obtain an initial fabric, where the pre-needling process and the main needling process are used for adjusting the web structure, and the cloth cover needling process is used for adjusting the surface density and thickness of the web. The method specifically comprises the following steps:
The needling depth of the pre-needling treatment is 3.0-12.5mm, and the needling density of the pre-needling treatment is 40-70 l per square meter;
The needling depth of the main needling treatment is 2.5-8.0mm, and the needling density of the main needling treatment is 120-200 l per square meter;
The needling depth of the needling treatment of the cloth cover is 2.0-7.0mm, and the needling density of the needling treatment of the cloth cover is 140-190 l per square meter.
Optionally, the needling depth of the pre-needling treatment is set at 3.0-3.5mm, in this example, optionally 3.5mm. The deeper needling depth helps to integrate the fibers initially, forming a preliminary fiber interwoven structure.
After the preliminary formation of the web, the preliminary needling treatment establishes basic inter-fiber association by the deep needling depth (3.0-12.5 mm) and lower needling density (40-70 l per square meter), preferably 6-10mm needling depth, 50-60 l per square meter, initially fixing the fibers in the web. The needling at this stage is intended to initially tailor the web structure to provide some stability and processability. The main needling treatment adopts needling depth (2.5-8.0 mm) and higher needling density (120-200 l per square meter), preferably needling depth of 4-6mm and density of 140-170 l per square meter, so as to further strengthen the interweaving degree of fibers in the fiber web and improve the overall strength and structural stability of the fiber web. Needling at higher densities can result in a more dense structure. The needling depth (2.0-7.0 mm) and density (140-190 l per square meter) of the cloth cover needling treatment are preferably 3-5mm, and the density is 160-160 l per square meter, which is mainly concentrated in the surface area of the fiber web, so as to optimize the density and thickness of the surface of the fiber web and improve the appearance and the hand feeling of the product. The treatment adjusts the distribution of surface fibers through slight surface needling, so that the cloth cover is smoother and denser.
The fiber web is strengthened from the internal structure through the step S109, the physical performance indexes such as strength, thickness, gram weight and elongation are improved, the high-quality requirement is met in the surface treatment, the dual standard of the cloth in the aspects of functionality and aesthetic property is ensured, and high-quality raw materials are provided for subsequent use or further processing. This stepwise approach represents a strict control over detail and quality in the nonwoven production process.
In one embodiment, step S110, heating by using circulated air in the closed space, and drying the initial cloth by controlling the oven temperatures of the upper area and the lower area of the cloth, where the drying is used to adjust the hardness of the cloth. The method specifically comprises the following steps:
And heating in the closed space by using fuel gas, and respectively controlling the oven temperatures of the upper area and the lower area of the cloth by using circulating air, wherein the oven temperatures of the upper area and the lower area of the cloth are controlled according to the characteristics of the cloth, the oven temperature of the upper area of the cloth is 0-220 ℃, and the oven temperature of the lower area of the cloth is 0-220 ℃.
Alternatively, the air in the closed space is heated using gas as a heat source, and the hot air is circulated in the space by a circulation fan. The design ensures that the heat is uniformly distributed, avoids local overheating, and improves the utilization efficiency of heat energy. According to the characteristics of the cloth, the oven temperatures of the upper area and the lower area of the cloth are independently controlled, the range is set to be 0 ℃ to 220 ℃, the oven temperature of the upper area of the cloth is preferably 180 ℃ to 190 ℃, the oven temperature of the lower area of the cloth is preferably 140 ℃ to 150 ℃, and the oven temperature of the upper area of the cloth is higher than the oven temperature of the lower area of the cloth. The temperature regulation mechanism is based on the understanding of the moisture evaporation rate, the fiber structure change and the hardness requirement in the cloth drying process. The upper temperature is often set higher to accelerate the evaporation of water and the reorientation of fibers, enhancing the hardness of the cloth; the lower temperature is relatively low, which helps to maintain softness and structural stability of the cloth and prevent damage caused by overheating of the bottom. With the action of circulating hot air, the moisture in the cloth is gradually evaporated, and the fiber is subjected to physical and chemical changes while losing the moisture, so that the fixation of the structure and the adjustment of hardness are promoted. The differential application of temperature accelerates this process and makes the final properties of the cloth more controllable.
Step S110 can accurately control the hardness of the dried cloth through the difference of the upper temperature and the lower temperature, and meets the requirements of different application scenes. The high temperature promotes the closer combination between the fibers and improves the hardness, while the low temperature is helpful for retaining the natural softness of the cloth. Not only optimizing the stoving effect of cloth, having ensured the hardness of product to satisfy specific demand, also improved production efficiency and energy utilization efficiency simultaneously.
In one embodiment, in step S111, the dried cloth is subjected to surface treatment by a hot roll, where the surface treatment is used to adjust the surface smoothness of the cloth. The method specifically comprises the following steps:
the oil in the two hot rolls is circularly heated by utilizing electric energy, the temperatures of the two hot rolls are respectively controlled, and roll treatment is carried out on the upper surface and the lower surface of the cloth, wherein the temperature of an upper roll in the hot rolls is 0-300 ℃, the temperature of a lower roll in the hot rolls is 0-300 ℃, and the speed of the hot rolls is 3-10 m/min.
Optionally, the oil in the hot roller is heated by electric energy and circularly flows, and the indirect heating mode can ensure that heat energy is uniformly distributed on the surface of the roller, so that local overheating or uneven cooling is avoided. The oil circulation also has good heat conduction and heat preservation effects, so that the temperature of the hot roller can be accurately controlled. The upper and lower hot rolls are respectively set with different temperature ranges (190-200 ℃ for the upper roll and 150-160 ℃ for the lower roll), and the temperature difference design can respectively carry out heat treatment on the upper surface and the lower surface of the cloth to different degrees according to the characteristics and the treatment requirements of the cloth. Higher temperatures facilitate plastic deformation and rearrangement of the fibers, while lower temperatures help maintain structural stability of the cloth and avoid excessive heat treatment. The speed range of the hot roller is set between 3m/min and 10m/min, and the speed is selected according to the thickness and the material of the cloth and the desired surface effect. The high speed is suitable for thinner or slightly flattened cloth, so that fiber damage can be reduced; slower speeds are suitable for fabrics that require deep flattening or thicker textures to ensure adequate heat transfer and surface flatness.
The surface treatment of the hot roller in the step S111 realizes the efficient leveling treatment of the surface of the dried cloth by accurate temperature and speed control, thereby not only improving the appearance quality of the cloth, but also optimizing the internal structure and functionality thereof, effectively eliminating the unevenness and fine wrinkles on the surface of the cloth and improving the smoothness and the aesthetic quality of the cloth. The rollers with different temperatures respectively act on the upper surface and the lower surface of the cloth, and can carry out accurate leveling treatment according to the requirements of different parts.
In one embodiment, before the product quality detection of the surface-treated fabric in step S113, the method further includes:
and step S112, uniformly powdering the surface of the cloth by a powdering machine.
Alternatively, the powdering device mechanically or pneumatically distributes the powder (e.g., starch, gum, or other chemicals) uniformly over the surface of the cloth. Such devices are often provided with accurate metering and distribution control systems to ensure uniformity of powder coverage, avoiding local overdosing or shortfalls. One of the main purposes of dusting is to improve the surface properties of the cloth. For example, the adhesive powder such as starch can be added to enhance the adhesion between fibers, improve the stability of the cloth cover and reduce the phenomena of hair falling or fiber falling; and some functional powder can endow cloth with waterproof, antistatic, antibacterial and other functions.
Step S112, powdering can improve the surface evenness and the hand feeling of the cloth, and the attractive appearance and the touch comfort of the product are improved.
In an embodiment, in step S113, product quality detection is performed on the cloth after surface treatment, and the cloth which does not meet the product quality standard is subjected to related adjustment, so as to obtain the cloth which meets the product quality standard, where the product quality detection includes detection of thickness, strength and elongation of the cloth, gram weight, softness and hardness of the cloth, surface smoothness of the cloth, and metal residue rate. The method specifically comprises the following steps:
under the condition that the thickness, shrinkage and gram weight of the cloth do not meet the quality standards, the needling depths and needling speeds of the pre-needling treatment, the main needling treatment and the cloth cover needling treatment are adjusted;
Adjusting the temperature of an oven in the upper area and the lower area of the cloth under the condition that the hardness degree of the cloth does not accord with the quality standard;
under the condition that the surface smoothness of the cloth does not accord with the quality standard, adjusting the parameters of the surface treatment of the hot roller;
And filtering the metal in the cloth under the condition that the metal residual rate of the cloth does not accord with the quality standard, and detecting the metal residual of each device.
Optionally, the parameters of the needling treatment (pre-needling, main needling, cloth cover needling) are adjusted by analyzing whether the thickness, strength, elongation and gram weight of the cloth reach the standards. The interlacing density and the structural compactness of the fibers can be influenced by adjusting the needling depth and the needling density, so that the thickness, the gram weight and the stability of the fibers of the cloth are indirectly controlled, and the strength and the elongation are changed. According to the detection result of the softness of the cloth, the temperature of the oven in the upper and lower areas of the cloth in the drying process is adjusted, and the binding force among the fibers and the physical state of the fibers are changed by utilizing the fine adjustment effect of the temperature on the fiber structure, so that the aim of adjusting the softness of the cloth is fulfilled. If the surface evenness does not reach the standard, parameters of hot roller treatment, including temperature, pressure, speed and the like of the hot roller are required to be adjusted so as to optimize the distribution of fibers on the surface, reduce wrinkles and unevenness, and improve the smoothness and uniformity of the cloth cover. And (3) aiming at the cloth with the exceeding metal residue rate, adopting a filtering measure to remove mixed metal impurities, and carrying out metal detection and cleaning on equipment in the whole production flow so as to prevent reintroduction of the metal impurities in future production and ensure the safety of products. In addition, when the powder scattering gram weight is uneven or the gram weight does not accord with the preset gram weight, the gram weight and the speed parameters of the powder scattering machine are adjusted, and the fiber arrangement can be adjusted through the drafting parameters of the drafting machine; the number of the single-layer fiber lapping layers can be adjusted by a lapping machine; the product grammage adjustment can be through carding machine lapping grammage parameter.
Step S113 not only solves the product quality problem of the current batch, but also accumulates precious experience for subsequent production by accurate detection and targeted adjustment strategy, thereby ensuring high quality and market competitiveness of the nonwoven fabric product. The cycle of detection and adjustment ensures that each step from raw material to finished product can be strictly monitored and optimized, a closed-loop system for quality control is formed, and the qualification rate and consistency of the final product are improved.
In an embodiment, after step S113, the method further comprises:
step S114 is to cut into products with specified widths through a cutting machine, and redundant slitter edges on two sides are cut off.
Alternatively, the slitter utilizes a sharp blade or laser cutting technique to precisely slit the continuous large area nonwoven into strips or blocks of product according to a predetermined width dimension. This process requires high precision positioning control and stable cutting speed to ensure that the cut edges are smooth, burr-free, and dimensionally accurate. The redundant slitter edges on the two sides are cut off, so that possible flaws or uneven parts on the edges of the cloth are removed, the parts possibly do not meet the quality requirements due to edge effects in the previous production process, and the overall quality of the product can be improved after the slitter edges are cut off.
And step S115, winding the product into a whole roll through a winding machine, and detecting qualified delivery by a quality part.
Alternatively, the winder closely and uniformly winds the slit nonwoven strips or blocks into rolls by mechanical means. This process involves speed control, tension control and monitoring of the winding diameter to ensure compactness, flatness and shape uniformity of the web. Before winding, there is usually a quality detection link (including but not limited to defect detection and rejection equipment, which rejects defects in the product and effectively controls defect and stain) to ensure that only acceptable products enter the winding process and reject defective products.
Step S114 and step S115 not only complete the transition of the product from large area to specified size, but also ensure high quality and standardization of the product through strict dimensional control and quality detection, laying a solid foundation for subsequent sales and use.
The following is a specific practical application example of the embodiment of the present application:
Example 1 in order to develop a 100gsm to 300gsm filter product as desired by a customer, it is required that the front and back sides be different in hardness and feel. In order to develop the product, the product can be reasonably set up the upper and lower temperatures of the oven and the upper and lower roller temperatures of the hot rolling mill by using the production line to achieve the purpose. The specific arrangement is as follows: the temperature of the upper area of the oven is 170-220 ℃, the temperature of the lower area of the oven is 80-130 ℃, the temperature of the upper roller of the hot rolling mill is 170-220 ℃, the temperature of the lower roller of the hot rolling mill is 80-130 ℃, the speed is controlled to be 6-7m/min, and the temperature can be properly reduced to 5-6m/min.
Example 2 to develop a 200gsm filter product as desired by a customer, it was desired that the front and back sides be different in hardness and feel. In order to develop the product, the product can be reasonably set up the upper and lower temperatures of the oven and the upper and lower roller temperatures of the hot rolling mill by using the production line to achieve the purpose. The specific arrangement is as follows: the temperature of the upper area of the oven is 195 ℃, the temperature of the lower area of the oven is 105 ℃, the temperature of the upper roller of the hot rolling mill is 195 ℃, the temperature of the lower roller is 105 ℃, and the speed is controlled to be 6-7m/min, so that the temperature can be properly reduced to 5-6m/min.
Example 3 to develop a product requiring 300gsm to 450gsm for a customer, one side is soft and one side is hard and not fluffed. In order to develop the product, the product can be reasonably set up the upper and lower temperatures of the oven and the upper and lower roller temperatures of the hot rolling mill by using the production line. The specific arrangement is as follows: the temperature of the upper region of the oven is 180-220 ℃, the temperature of the lower region of the oven is 145-165 ℃, the temperature of the upper roller of the hot rolling mill is 180-220 ℃, the temperature of the lower roller is 145-165 ℃, the speed is controlled between 3m/min and 4m/min, and the speed can be properly reduced.
Example 4 to develop a product requiring 375gsm for a customer, it is desirable to have a soft and hard side without fluff. In order to develop the product, the product can be reasonably set up the upper and lower temperatures of the oven and the upper and lower roller temperatures of the hot rolling mill by using the production line. The specific arrangement is as follows: the temperature of the upper area of the oven is 200 ℃, the temperature of the lower area of the oven is 155 ℃, the temperature of the upper roller of the hot rolling mill is 200 ℃, the temperature of the lower roller is 155 ℃, and the speed is controlled between 3m/min and 4m/min, and can be properly reduced.
In summary, according to the quality control method for the needled non-woven fabric provided by the embodiment of the application, the fiber web is sequentially subjected to the pre-needling treatment, the main needling treatment and the cloth cover needling treatment to obtain initial cloth, wherein the pre-needling treatment and the main needling treatment are used for adjusting the fiber web structure, and the cloth cover needling treatment is used for adjusting the surface density and the thickness of the fiber web; heating the initial cloth in the closed space by using circulating air, and drying the initial cloth by controlling the temperature of a drying oven in an upper area and a lower area of the cloth, wherein the drying is used for adjusting the hardness degree of the cloth; carrying out surface treatment on the dried cloth by a hot roller, wherein the surface treatment is used for adjusting the surface smoothness of the cloth; and carrying out product quality detection on the cloth subjected to surface treatment, and carrying out relevant adjustment on the cloth which does not meet the product quality standard to obtain the cloth which meets the product quality standard, wherein the product quality detection comprises detection of the thickness, the strength and the elongation, the gram weight, the softness and hardness degree of the cloth, the surface smoothness degree of the cloth and the metal residual rate of the cloth, so that the quality control of the existing needled non-woven fabric is realized, the quality of the non-woven fabric is effectively improved, and the problem of low quality of the existing needled non-woven fabric in the relevant technology is solved.
The beneficial effects of the invention also include: the proportion of raw materials is accurately controlled by a computer weighing system during unpacking, so that the accuracy of the formula is ensured. Before the material enters the large bin, a metal detector is used for detecting whether metal exists in the material, so that the safety of the material is ensured; when the large bins are mixed, the materials are fully mixed through circulating air outlet of a special fan, so that the gram weight uniformity of the materials is ensured; the pneumatic cotton box is accurately weighed by a belt scale before entering the carding machine, so that the gram weight is ensured to be uniform; before winding, metal and defect detection and removal equipment is added to remove defects in the product, so that defects and stains are effectively controlled. Under the effective control of the process, the product can reach the expected quality standard, the production loss of downstream products and consumer complaints are greatly reduced, the gram weight of the products is stable, the strength and elongation indexes reach the standards, and defects, metals and stains can be effectively removed.
The method can bring the following practical benefits:
1. The rejection rate of the needled non-woven fabric is reduced, the rejection rate can be effectively reduced to below 6%, the production cost and the labor cost are indirectly reduced for enterprises, the production time is saved, and the production efficiency is improved.
2. And the price is improved due to stable quality. Because the quality is stable, the method can be sold to high-end enterprises insensitive to price, opens application markets and improves enterprise profits.
3. Indirectly improves the competitiveness of enterprises. The quality is stable, customer complaints and consumer complaints can be reduced, the image and the competitiveness of enterprises are improved, and fund assurance is provided for long-term development of the enterprises.
The technical features of the above embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The foregoing examples illustrate only a few embodiments of the application, which are described in detail and are not to be construed as limiting the scope of the application. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the application, which are all within the scope of the application. Accordingly, the scope of protection of the present application is to be determined by the appended claims.
Claims (10)
1. A method for controlling the quality of a needled nonwoven fabric, comprising:
the method comprises the steps of sequentially carrying out pre-needling treatment, main needling treatment and cloth cover needling treatment on a fiber net to obtain initial cloth, wherein the pre-needling treatment and the main needling treatment are used for adjusting the structure of the fiber net, and the cloth cover needling treatment is used for adjusting the surface density and the thickness of the fiber net;
heating the initial cloth in the closed space by using circulating air, and drying the initial cloth by controlling the temperature of a drying oven in an upper area and a lower area of the cloth, wherein the drying is used for adjusting the hardness degree of the cloth;
carrying out surface treatment on the dried cloth by a hot roller, wherein the surface treatment is used for adjusting the surface smoothness of the cloth;
And carrying out product quality detection on the cloth subjected to surface treatment, and carrying out relevant adjustment on the cloth which does not meet the product quality standard to obtain the cloth which meets the product quality standard, wherein the product quality detection comprises detection of the thickness, the strength and the elongation of the cloth, the gram weight, the softness and hardness degree of the cloth, the surface smoothness degree of the cloth and the metal residual rate.
2. The method of claim 1, wherein the step of performing a correlation adjustment on the fabric that does not meet the product quality criteria to obtain a fabric that meets the product quality criteria comprises:
adjusting needling depths and needling densities of the pre-needling treatment, the main needling treatment and the cloth cover needling treatment under the condition that the thickness, the strength and the elongation of the cloth do not meet quality standards;
Adjusting the temperature of an oven in the upper area and the lower area of the cloth under the condition that the hardness degree of the cloth does not accord with the quality standard;
under the condition that the surface smoothness of the cloth does not accord with the quality standard, adjusting the parameters of the surface treatment of the hot roller;
And filtering the metal in the cloth under the condition that the metal residual rate of the cloth does not accord with the quality standard, and detecting the metal residual of each device.
3. The method of claim 1, wherein the step of determining the position of the substrate comprises,
The needling depth of the pre-needling treatment is 3.0-12.5mm, and the needling density of the pre-needling treatment is 40-70 l per square meter;
The needling depth of the main needling treatment is 2.5-8.0mm, and the needling density of the main needling treatment is 120-200 l per square meter;
The needling depth of the needling treatment of the cloth cover is 2.0-7.0mm, and the needling density of the needling treatment of the cloth cover is 140-190 l per square meter.
4. The method of claim 1, wherein the heating in the closed space using circulated air and drying the initial cloth by controlling the oven temperature of the upper cloth area and the lower cloth area comprises:
And heating in the closed space by using fuel gas, and respectively controlling the oven temperatures of the upper area and the lower area of the cloth by using circulating air, wherein the oven temperatures of the upper area and the lower area of the cloth are controlled according to the characteristics of the cloth, the oven temperature of the upper area of the cloth is 0-220 ℃, and the oven temperature of the lower area of the cloth is 0-220 ℃.
5. The method according to claim 1, wherein the dried cloth is subjected to a surface treatment by a hot roll, the surface treatment being used for adjusting the surface smoothness of the cloth, comprising:
the oil in the two hot rolls is circularly heated by utilizing electric energy, the temperatures of the two hot rolls are respectively controlled, and roll treatment is carried out on the upper surface and the lower surface of the cloth, wherein the temperature of an upper roll in the hot rolls is 0-300 ℃, the temperature of a lower roll in the hot rolls is 0-300 ℃, and the speed of the hot rolls is 3-10 m/min.
6. The method of claim 1, wherein prior to the product quality inspection of the surface treated fabric, the method further comprises:
And uniformly powdering the surface of the cloth by a powdering machine.
7. The method of claim 1, wherein prior to subjecting the web to the pre-needling, the main needling, and the face needling in that order to obtain the initial fabric, the method further comprises:
Different kinds of fibers are put into different bale openers according to the production formula, and the proportion of the input materials is controlled;
Carrying out metal detection on different kinds of fibers passing through an unpacking machine, and carrying out initial mixing and opening on detected raw materials through a mixing large bin;
further mixing and finely opening the fibers mixed by the big bin;
sucking the mixed and opened fibers into a cotton storage box through a fan for storage for later use;
And (3) conveying the fibers of the cotton storage box to a pneumatic cotton box through a powerful fan, and accurately weighing the fibers through a belt scale.
8. The method of claim 7, wherein after the fibers of the hopper are fed to the pneumatic hopper by a powerful fan and precisely weighed by a belt scale, the method further comprises:
And carding the weighed different fibers into a single-layer fiber web which is arranged in a crossing way and uniformly mixed by a carding machine.
9. The method of claim 8, wherein carding the weighed different fibers into a cross-aligned, uniformly mixed single layer web by a carding machine comprises:
The single-layer fiber web is paved into a multi-layer fiber web with a preset layer number and uniform thickness through a lapping machine, and the multi-layer fiber web is lapped.
10. The method of claim 9, wherein after the single-layer web is laid by a lapping machine into a multi-layer web of a predetermined number of layers and uniform thickness, the multi-layer web is lapped, the method further comprises:
The fiber arrangement mode is changed through a drawing machine, and the fiber web is arranged differently.
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