TW202136609A - Method for fabricating three-dimensional nonwoven fabric - Google Patents

Abstract

A method for fabricating a three-dimensional nonwoven fabric includes following steps. Meltblown fibers are sprayed by a meltblown device, in which a single-hole ejection rate of the meltblown fibers is in a range from 0.01 g/min to 0.5 g/min. A first portion of the meltblown fibers is received by a roller device. A second portion of the meltblown fibers is received by a collecting device, in which the collecting device has a receiving net, and a moving rate of the receiving net is in a range from 1 m/min to 5 m/min. The first portion of the meltblown fibers reaches the collecting device through a rotation of the roller device.

Description

Method for manufacturing three-dimensional non-woven fabric

The content of the disclosure relates to a method for manufacturing a three-dimensional non-woven fabric, and particularly to a method for manufacturing a three-dimensional non-woven fabric with high bulkiness.

In the textile industry, since non-woven fabrics can be formed without warp knitting, issues related to non-woven fabrics have become the focus of development. In addition, non-woven fabrics have the advantages of short process time, high output, low cost, and wide source of raw materials, so they are suitable for application in the consumer market. The broad definition of non-woven fabric can be a cloth formed by pressure or by viscosity. However, the manufacturing process of the non-woven fabric can have quite a lot of changes, and as the manufacturing method changes, the properties of the non-woven fabric will also change accordingly.

With the continuous development of the textile industry, the industry began to develop non-woven fabrics with a three-dimensional structure. However, limited by the design of current textile equipment, the bulkiness and thickness of the three-dimensional non-woven fabric cannot be effectively improved. Therefore, how to provide a three-dimensional non-woven fabric with high bulkiness and thickness is a very important subject at present.

According to an embodiment of the present disclosure, the manufacturing method of the three-dimensional non-woven fabric includes the following steps. The melt-blown fiber is sprayed by a melt-blown device, and the single-hole ejection rate of the melt-blown fiber is between 0.01 g/min and 0.50 g/min. The first part of the melt-blown fiber is received by the roller device. The second part of the meltblown fiber is received by the collecting device, wherein the collecting device has a receiving net, and the moving speed of the receiving net is between 1 m/min to 5 m/min. Through the rotation of the roller device, the first part of the meltblown fiber reaches the collecting device.

In some embodiments of the present disclosure, the meltblown device has a plurality of ejection holes, and the density of the ejection holes is between 35 holes/inch and 65 holes/inch.

In some embodiments of the present disclosure, the melt blowing device sprays molten fibers perpendicular to the receiving surface of the collecting device.

In some embodiments of the present disclosure, the method for manufacturing the three-dimensional nonwoven fabric further includes rotating the roller device to make the first part of the meltblown fiber pass between the roller device and the collecting device.

In some embodiments of the present disclosure, the method for manufacturing the three-dimensional non-woven fabric further includes the rotation of the roller device and the transportation of the collecting device to make the meltblown fiber pass between the roller device and the collecting device to form the three-dimensional non-woven fabric.

In some embodiments of the present disclosure, when the roller device rotates, the tangential direction of the side of the roller device adjacent to the collecting device is the same as the conveying direction of the receiving surface of the collecting device.

In some embodiments of the present disclosure, the vertical distance between the roller device and the collection device is between 10 mm and 100 mm.

In some embodiments of the present disclosure, the bulkiness of the three-dimensional non-woven fabric is between 150 cubic inches/ounce and 600 cubic inches/ounce.

In some embodiments of the present disclosure, the basis weight of the three-dimensional non-woven fabric is between 25 g/m² and 550 g/m².

In some embodiments of the present disclosure, the material of the melt-blown fiber includes polyolefin, polyester, polyurethane, and nylon, and the diameter of the melt-blown fiber in the three-dimensional non-woven fabric is between 0.2 μm and 20 μm.

According to the above-mentioned embodiment of the present disclosure, the method for manufacturing the three-dimensional nonwoven fabric makes the first part of the melt-blown fiber reach the receiving net of the collection device through the rotation of the roller device, and passes through the roller device and the collection device together with the second part of the melt-blown fiber Between, thus forming a three-dimensional non-woven fabric. By adjusting the moving speed of the receiving net in an appropriate range, the formed three-dimensional non-woven fabric can have a certain thickness and good bulkiness.

Hereinafter, a plurality of implementation manners of the present disclosure will be disclosed in diagrams. For the sake of clarity, many practical details will be described in the following description. However, it should be understood that these practical details should not be used to limit this disclosure. That is to say, in some implementations of this disclosure, these practical details are unnecessary, and therefore should not be used to limit this disclosure. In addition, in order to simplify the drawings, some conventionally used structures and elements are shown in the drawings in a simple and schematic manner. In addition, for the convenience of readers, the size of each element in the drawings is not drawn according to actual scale.

The present disclosure provides a method for manufacturing a three-dimensional non-woven fabric, which is completed by a textile device with a roller device. Through the rotation of the roller device, part of the melt blown fiber can be pulled by the roller device before reaching the collection device, so that the manufactured three-dimensional non-woven fabric has a certain thickness and good bulkiness.

Fig. 1 is a schematic side view of a textile equipment 100 according to an embodiment of the present disclosure. The textile equipment 100 includes a melt blowing device 110, a collecting device 120 and a roller device 130. The melt-blown device 110 is configured to spray melt-blown fibers F. In some embodiments, the melt-blown device 110 has at least one ejection hole 112, and the melt-blown fiber F is ejected from the ejection hole 112. The collecting device 120 is configured to collect the melt-blown fibers F sprayed by the melt-blown device 110. In some embodiments, the collection device 120 has a receiving net 122 and a conveying element 124. The receiving net 122 is disposed on the surface of the conveying element 124 to receive the meltblown fiber F without interruption through the driving of the conveying element 124. Specifically, the conveying element 124 may be, for example, a combination of a conveying roller and a conveying belt. In some embodiments, the collecting device 120 has a suction element 126 disposed on the other side of the conveying element 124 relative to the receiving net 122 to provide suction to guide the meltblown fiber F to the receiving net 122. The roller device 130 is disposed between the melt-blown device 110 and the collection device 120 and is configured to receive part of the melt-blown fiber F, and rotates so that the received melt-blown fiber F reaches the collection device 120.

FIG. 2 is a schematic side view of the textile device 100 of FIG. 1, wherein the viewing angle direction of FIG. 2 is perpendicular to the viewing angle direction of FIG. 1. In some embodiments, the melt blowing device 110 has a plurality of discharge holes 112, and the arrangement direction of the plurality of discharge holes 112 is parallel to the extending direction of the roller device 130. In some embodiments, the collecting device 120 can support the roller device 130 through the connecting element 140, and the connecting element 140 can be electrically connected to the collecting device 120 and the roller device 130, and further electrically connected to a central system such as a computer ( Not shown), so as to transmit the movement of the receiving net 122 and the rotation of the roller device 130 to the central system in real time for proper control.

Fig. 3 shows a flow chart of manufacturing a three-dimensional non-woven fabric using the weaving equipment 100 of Fig. 1. The manufacturing method of the three-dimensional nonwoven fabric includes steps S10, S20, S30, and S40. In step S10, melt-blown fibers are sprayed with a melt-blown device. In step S20, a roller device is used to receive the first part of the melt-blown fiber. In step S30, the second part of the melt-blown fiber is received by the collecting device. In step S40, the first part of the meltblown fiber reaches the collecting device through the rotation of the roller device. In the following description, the above-mentioned steps will be further explained.

Please refer to FIG. 1 and FIG. 3 at the same time. In step S10, the textile equipment 100 sprays the melt-blown fiber F through the discharge hole 112 of the melt-blown device 110. In some embodiments, the single hole ejection rate of the meltblown fiber F is between 0.01 g/min and 0.50 g/min. In some embodiments, when the meltblowing device 110 has a plurality of ejection holes 112, the density of the ejection holes 112 is between 35 holes/inch and 65 holes/inch. With the above configuration, it can be ensured that the melt-blown device 110 discharges a certain weight of the melt-blown fiber F per unit time, so that the formed three-dimensional non-woven fabric 200 has an appropriate basis weight.

In some embodiments, the melt blown device 110 sprays the melt blown fiber F perpendicular to the receiving surface of the collection device 120, wherein the receiving surface is the surface of the receiving net 122 facing the discharge hole 112. In this way, when the receiving surface is parallel to the ground, the meltblown fiber F can easily fall onto the collecting device 120 and the roller device 130 between the meltblown device 110 and the collecting device 120 due to the influence of gravity. In some embodiments, the diameter of the meltblown fiber F in the formed three-dimensional nonwoven fabric 200 is between 0.2 μm and 20 μm. In some embodiments, the material of the meltblown fiber F includes polyolefin, polyester, polyurethane, nylon, or any combination of the foregoing. By selecting appropriate materials, the formed three-dimensional non-woven fabric 200 can have corresponding uses. For example, if polyolefin is used, the formed three-dimensional non-woven fabric 200 can be used as a sound-absorbing and noise-reducing material; if polyester is used, the formed three-dimensional non-woven fabric 200 can be used as a thermal insulation material.

In step S20, the textile equipment 100 uses the roller device 130 to receive the first part F1 of the meltblown fiber F. Next, in step S30, the textile equipment 100 uses the collecting device 120 to receive the second part F2 of the meltblown fiber F. In detail, since the roller device 130 is located between the melt-blown device 110 and the collection device 120, and the roller device 130 and the melt-blown device 110 only partially overlap, when the melt-blown device 110 sprays the melt-blown fiber F, the melt-blown fiber F is melted. The first part F1 of the sprayed fiber F will reach the roller device 130 first, and the second part F2 of the melt-blown fiber F will directly reach the receiving net 122 of the collection device 120.

After the first part F1 of the meltblown fiber F reaches the roller device 130, in step S40, the first part F1 of the meltblown fiber F is rotated by the roller device 130 to reach the collecting device 120. Then, the first part F1 of the meltblown fiber F arriving at the collecting device 120 is rotated by the roller device 130 to move between the roller device 130 and the collecting device 120, and pass between the roller device 130 and the collecting device 120. At the same time, when the second part F2 of the melt-blown fiber F reaches the collecting device 120, the second part F2 of the melt-blown fiber F is transported by the conveying element 124 of the collecting device 120 to the roller device 130 and the collecting device 120. And pass between the roller device 130 and the collection device 120. In other words, through the rotation of the roller device 130 and the transportation of the collecting device 120, the meltblown fiber F can pass between the roller device 130 and the collecting device 120 as a whole, thereby forming the three-dimensional non-woven fabric 200.

In some embodiments, when the roller device 130 rotates, the tangential direction of the side of the roller device 130 adjacent to the collecting device 120 is the same as the conveying direction of the receiving surface of the collecting device 120. Thereby, each meltblown fiber F passing between the roller device 130 and the collecting device 120 can move in the same direction, so that the formed three-dimensional non-woven fabric 200 has a neat and stable structure, and can make the three-dimensional non-woven fabric 200 have a neat and stable structure. The melt-blown fiber F has a meniscus-like structure with the same direction. The meltblown fibers F having a meniscus-like structure can be used as air chambers to contain air, thereby increasing the bulkiness of the three-dimensional non-woven fabric 200.

In some embodiments, the moving speed of the receiving net 122 of the collection device 120 is between 1 m/min and 5 m/min. By adjusting the moving speed of the receiving net 122 of the collecting device 120 in the above-mentioned appropriate range, the formed three-dimensional non-woven fabric 200 can have a better thickness H. In detail, if the moving speed of the receiving net 122 is too large, the melt blown fiber F that the receiving net 122 can receive per unit area is too small, so that the formed three-dimensional non-woven fabric 200 is too thin; if the moving speed of the receiving net 122 is too small , The receiving net 122 can receive too many meltblown fibers F per unit area, so that the formed three-dimensional non-woven fabric 200 is too thick. In addition, if the moving speed of the receiving web 122 is too large, the formed three-dimensional nonwoven fabric 200 will not be able to form a highly entangled fiber web due to the insufficient number of meltblown fibers F, thereby affecting the stability of the three-dimensional nonwoven fabric 200 structure.

In some embodiments, the vertical distance L between the roller device 130 and the collection device 120 is between 10 mm and 100 mm. By adjusting the vertical distance L between the roller device 130 and the collecting device 120 within the above-mentioned appropriate range, the formed three-dimensional non-woven fabric 200 can also have a better thickness H. Specifically, the vertical distance L between the roller device 130 and the collection device 120 can determine the stack thickness of the meltblown fiber F passing therethrough, and therefore can affect the thickness H of the formed three-dimensional nonwoven fabric 200. In some embodiments, the thickness H of the three-dimensional non-woven fabric 200 is between 0.5 mm and 100 mm.

In some embodiments, the combination of the base fabric weight of the three-dimensional non-woven fabric 200 and the thickness H of the three-dimensional non-woven fabric 200 can make the three-dimensional non-woven fabric 200 have good bulkiness. As mentioned above, since the base fabric weight of the three-dimensional non-woven fabric 200 is related to the single-hole ejection rate of the meltblown fiber F, the thickness H of the three-dimensional non-woven fabric 200 and the moving rate of the receiving net 122 and the distance between the roller device 130 and the collecting device 120 The vertical distance L is related to the vertical distance L. Therefore, the vertical distance L between the roller device 130 and the collecting device 120 can be adjusted in an appropriate range by adjusting the single hole ejection rate of the meltblown fiber F, the moving speed of the receiving net 122, and the vertical distance L between the roller device 130 and the collecting device 120. To improve the bulkiness of the three-dimensional non-woven fabric 200. In some embodiments, the base fabric weight of the three-dimensional non-woven fabric 200 is between 25 g/m² and 550 g/m². In some embodiments, the bulkiness of the three-dimensional nonwoven fabric 200 is between 150 cubic inches/ounce and 600 cubic inches/ounce.

In the following description, the three-dimensional non-woven fabrics of Examples 1 to 6 and Comparative Example 1 of the present disclosure will be further described. The three-dimensional non-woven fabric of each embodiment is manufactured by performing steps S10 to S40, while the comparative example is manufactured by a conventional double-roller spinning equipment in a conventional procedure. The detailed description of each embodiment and comparative example is shown in Table 1.

Table I Single hole discharge rate of melt blown fiber (g/min) Moving speed of the undertaking network (m/min) Example 1 0.25~0.30 3.0 Example 2 0.25~0.30 3.0 Example 3 0.25~0.30 3.0 Example 4 0.35~0.40 3.0 Example 5 0.35~0.40 3.0 Example 6 0.15~0.20 2.0 Comparative example 1 0.15~0.20 2.0

Next, measure the base fabric weight, thickness, bulkiness, compression recovery rate, horizontal tensile strength and horizontal peel strength of the three-dimensional nonwoven fabrics of Examples 1 to 6 and Comparative Example 1 of the present disclosure to further verify The efficacy of the present disclosure and the test results are shown in Table 2 below.

Table II Base cloth weight (g/m ² ) Thickness(mm) Bulkiness (in ³ /oz) Compression recovery rate (%) Horizontal tensile strength (N) Horizontal peel strength (N) Example 1 292.9 27.3 153.34 100.0 10.866 6.973 Example 2 298.3 29.5 169.82 100.0 10.209 6.139 Example 3 299.6 47.7 281.90 100.0 9.061 6.071 Example 4 300.5 85.0 479.23 96.3 8.110 4.864 Example 5 306.9 100 563.79 93.4 7.943 4.374 Example 6 207.1 29.3 246.86 88.4 4.129 2.530 Comparative example 1 184.9 1.1 10.29 Unmeasured Unmeasured Unmeasured

It can be seen from Table 2 that after manufacturing for the same time, the three-dimensional nonwoven fabrics of Examples 1 to 6 have larger base fabric weight, thickness and better bulk than the three-dimensional nonwoven fabrics of Comparative Example 1. In addition, the three-dimensional non-woven fabrics of Examples 1 to 6 have good compression recovery rates, that is, the three-dimensional non-woven fabrics have good elasticity. In addition, the three-dimensional non-woven fabrics of Examples 1 to 6 have certain horizontal tensile strength and horizontal peel strength, that is, the three-dimensional non-woven fabrics have a stable structure.

According to the above-mentioned embodiments of the present disclosure, the spinning equipment allows the first part of the melt-blown fiber to reach the collecting device through the rotation of the roller device and pass between the roller device and the collecting device together with the second part of the melt-blown fiber, thereby forming a three-dimensional non-woven fabric . By adjusting the moving speed of the receiving net of the collection device, the single hole ejection rate of the meltblown fiber, and the vertical distance between the roller device and the collection device within an appropriate range, the formed three-dimensional non-woven fabric can have a certain thickness And good bulkiness.

Although the present disclosure has been disclosed in the above implementation manner, it is not intended to limit the present disclosure. Anyone with ordinary knowledge in the technical field to which the present disclosure belongs can make various changes and changes without departing from the spirit and scope of the present disclosure. Retouching, therefore, the scope of protection of this disclosure shall be subject to the scope of the attached patent application.

100: Textile equipment 110: Meltblown device 112: spit hole 120: Collection device 122: Undertake Network 124: Conveying element 126: Suction element 130: Roller device 140: connection element 200: Three-dimensional non-woven fabric F: Meltblown fiber F1: Part One F2: Part Two L: distance H: thickness S10~S40: steps

In order to make the above and other objectives, features, advantages and embodiments of the present disclosure more obvious and understandable, the description of the accompanying drawings is as follows: Figure 1 is a schematic side view of a textile equipment according to an embodiment of the present disclosure. Figure 2 is a schematic side view of the textile equipment of Figure 1, wherein the viewing angle direction of Figure 2 is perpendicular to the viewing angle direction of Figure 1. Figure 3 shows a flow chart of using the textile equipment of Figure 1 to manufacture three-dimensional non-woven fabrics.

Domestic deposit information (please note in the order of deposit institution, date and number) without Foreign hosting information (please note in the order of hosting country, institution, date, and number) without

100: Textile equipment

110: Meltblown device

112: spit hole

120: Collection device

122: Undertake Network

124: Conveying element

126: Suction element

130: Roller device

200: Three-dimensional non-woven fabric

F: Meltblown fiber

F1: Part One

F2: Part Two

L: distance

H: thickness

Claims (10)

A method for manufacturing three-dimensional non-woven fabric, including: The melt-blown fiber is sprayed by a melt-blown device, wherein the single-hole ejection rate of the melt-blown fiber is between 0.01 g/min and 0.50 g/min; Receiving the first part of the melt-blown fiber with a roller device; Receiving the second part of the melt blown fiber with a collecting device, wherein the collecting device has a receiving net, and the moving speed of the receiving net is between 1 m/min to 5 m/min; and Through the rotation of the roller device, the first part of the melt-blown fiber reaches the collecting device. The method for manufacturing a three-dimensional nonwoven fabric according to claim 1, wherein the meltblown device has a plurality of ejection holes, and the density of the ejection holes is between 35 holes/inch and 65 holes/inch. The method for manufacturing a three-dimensional nonwoven fabric according to claim 1, wherein the melt-blown device sprays the melt-blown fiber perpendicular to the receiving surface of the collection device. The method for manufacturing the three-dimensional nonwoven fabric according to claim 1, further comprising passing the first part of the melt blown fiber between the roller device and the collecting device through the rotation of the roller device. The method for manufacturing a three-dimensional nonwoven fabric according to claim 1, further comprising passing the melt blown fiber between the roller device and the collecting device through the rotation of the roller device and the transportation of the collecting device, To form the three-dimensional non-woven fabric. The method of manufacturing a three-dimensional non-woven fabric according to claim 1, wherein when the roller device rotates, the tangential direction of the side of the roller device adjacent to the collecting device is the same as the receiving surface of the collecting device. The conveying direction is the same. The method for manufacturing a three-dimensional nonwoven fabric according to claim 1, wherein the vertical distance between the roller device and the collecting device is between 10 mm and 100 mm. The method for manufacturing a three-dimensional non-woven fabric according to claim 1, wherein the bulkiness of the three-dimensional non-woven fabric is between 150 cubic inches/ounce and 600 cubic inches/ounce. The method for manufacturing a three-dimensional non-woven fabric according to claim 1, wherein the basis weight of the three-dimensional non-woven fabric is between 25 g/m² and 550 g/m². The method for manufacturing a three-dimensional non-woven fabric according to claim 1, wherein the material of the melt-blown fiber includes polyolefin, polyester, polyurethane, and nylon, and the diameter of the melt-blown fiber in the three-dimensional non-woven fabric is between 0.2 micrometers To 20 microns.

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