TWI760713B - 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

Manufacturing method of three-dimensional non-woven fabric

The present disclosure relates to a method for manufacturing a three-dimensional non-woven fabric, and in particular, to a method for manufacturing a three-dimensional non-woven fabric with high bulkiness.

In the field of textile industry, since non-woven fabrics can be formed without weaving, 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 yield, low cost, and wide source of raw materials, so they are suitable for use in the consumer market. A broad definition of nonwoven can be a cloth-like object formed by pressure or by stickiness. However, the manufacturing process of non-woven fabrics can vary substantially, and the properties of non-woven fabrics will also change along with the changes in the manufacturing process.

With the development of the textile industry, the industry has begun to develop non-woven fabrics with three-dimensional structures. However, limited by the design of the 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 nonwoven fabric with high bulkiness and thickness is a very important issue at present.

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

In some embodiments of the present disclosure, the meltblown device has a plurality of discharge holes, and the density of the discharge holes ranges from 35 holes/inch to 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 manufacturing method of the three-dimensional non-woven fabric further includes passing the first part of the meltblown fibers between the roller device and the collecting device through the rotation of the roller device.

In some embodiments of the present disclosure, the manufacturing method of the three-dimensional non-woven fabric further includes the rotation of the roller device and the conveying of the collecting device to make the meltblown fibers 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 collecting 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 materials of the melt-blown fibers include polyolefin, polyester, polyurethane and nylon, and the diameter of the melt-blown fibers in the three-dimensional non-woven fabric is between 0.2 μm and 20 μm.

According to the above-mentioned embodiments of the present disclosure, the manufacturing method of the three-dimensional non-woven fabric is through the rotation of the roller device, so that the first part of the melt-blown fiber reaches the receiving net of the collecting device, and passes through the roller device and the collecting 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.

Several embodiments of the present disclosure will be disclosed in the following drawings, and for the sake of clarity, many practical details will be described together in the following description. It should be understood, however, that these practical details should not be used to limit the present disclosure. That is to say, in some embodiments of the present disclosure, these practical details are unnecessary, and therefore should not be used to limit the present disclosure. In addition, for the purpose of simplifying the drawings, some well-known structures and elements will be shown in a simple and schematic manner in the drawings. In addition, for the convenience of the reader, the size of each element in the drawings is not drawn according to the actual scale.

The present disclosure provides a manufacturing method of a three-dimensional non-woven fabric, which is completed by a textile equipment having a roller device. Through the rotation of the roller device, part of the meltblown fibers can be pulled by the roller device before reaching the collecting device, so that the produced three-dimensional nonwoven fabric has a certain thickness and good bulkiness.

FIG. 1 is a schematic side view of a textile apparatus 100 according to an embodiment of the present disclosure. The textile apparatus 100 includes a melt blowing device 110 , a collecting device 120 and a roller device 130 . Meltblown device 110 is configured to spray meltblown fibers F. In some embodiments, the meltblown device 110 has at least one discharge hole 112 , and the meltblown fibers F are sprayed from the discharge hole 112 . The collection device 120 is configured to collect the meltblown fibers F sprayed by the meltblown device 110 . In some embodiments, the collecting 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 continuously receive the meltblown fibers F driven by the conveying element 124 . Specifically, the conveying element 124 may be, for example, a combination of conveying rollers and conveying belts. In some embodiments, the collection device 120 has a suction element 126 disposed on the other side of the conveying element 124 relative to the receiving web 122 to provide suction to guide the meltblown fibers F to the receiving web 122 . The roller device 130 is disposed between the melt-blown device 110 and the collection device 120 , and is configured to receive a portion of the melt-blown fibers F, and rotate to make the received melt-blown fibers F reach the collection device 120 .

FIG. 2 is a schematic side view of the textile apparatus 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 electrically connect the collecting device 120 and the roller device 130, and further electrically connect to a central system such as a computer ( (not shown), so that the movement of the receiving net 122 and the rotation of the roller device 130 are instantly transmitted to the central system for proper regulation.

FIG. 3 shows a flow chart of manufacturing a three-dimensional non-woven fabric using the textile 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, the first portion of the meltblown fiber is received with a roller device. In step S30, the second portion of the meltblown fibers is received with a collecting device. In step S40, the first portion of the meltblown fibers 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 fibers F through the discharge holes 112 of the melt-blown device 110 . In some embodiments, the per-hole discharge rate of the meltblown fibers F is between 0.01 g/min and 0.50 g/min. In some embodiments, when the meltblown device 110 has a plurality of discharge holes 112, the density of the discharge holes 112 is between 35 holes/inch and 65 holes/inch. With the above configuration, it can be ensured that the meltblown device 110 discharges a certain weight of meltblown fibers F per unit time, so that the formed three-dimensional nonwoven fabric 200 has an appropriate basis weight.

In some embodiments, the melt-blown device 110 sprays the melt-blown fibers F perpendicular to the receiving surface of the collecting device 120 , wherein the receiving surface is the surface of the receiving mesh 122 facing the discharge hole 112 . In this way, when the bearing surface is parallel to the ground, the meltblown fibers F can easily fall to 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 fibers F in the formed three-dimensional nonwoven fabric 200 is between 0.2 microns and 20 microns. In some embodiments, the material of the meltblown fiber F includes polyolefin, polyester, polyurethane, nylon, or any combination thereof. 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 absorption and noise reduction 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 spinning apparatus 100 receives the first portion F1 of the meltblown fibers F with the roller device 130 . Next, in step S30 , the textile equipment 100 receives the second portion F2 of the meltblown fibers F with the collecting device 120 . In detail, since the roller device 130 is located between the meltblown device 110 and the collection device 120, and the roller device 130 and the meltblown device 110 only partially overlap, after the meltblown fiber F is sprayed by the meltblown device 110, the meltblown fiber F is The first part F1 of the blown fibers F will reach the roller device 130 first, and the second part F2 of the melt-blown fibers F will directly reach the receiving web 122 of the collecting device 120 .

After the first part F1 of the melt-blown fibers F reaches the roller device 130 , in step S40 , the first part F1 of the melt-blown fibers F is rotated by the roller device 130 to reach the collecting device 120 . Next, the first portion F1 of the meltblown fibers F reaching the collecting device 120 is rotated by the roller device 130 to move between the roller device 130 and the collecting device 120 , and passes between the roller device 130 and the collecting device 120 . At the same time, after the second part F2 of the melt-blown fibers F reaches the collecting device 120 , the second part F2 of the melt-blown fibers F is conveyed by the conveying element 124 of the collecting device 120 to the space between the roller device 130 and the collecting device 120 move between, and pass between the roller device 130 and the collecting device 120 . In other words, through the rotation of the roller device 130 and the conveyance of the collecting device 120 , the meltblown fibers F can pass through between the roller device 130 and the collecting device 120 as a whole, thereby forming the three-dimensional nonwoven 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 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 . The meltblown fibers F have a meniscus-like structure with a uniform direction. The meltblown fibers F with the meniscus structure can be used as air chambers to accommodate air, so as to improve the bulkiness of the three-dimensional nonwoven fabric 200 .

In some embodiments, the rate of movement of the receiving web 122 of the collection device 120 is between 1 m/min to 5 m/min. By adjusting the moving speed of the receiving net 122 of the collecting device 120 within the above-mentioned appropriate range, the three-dimensional non-woven fabric 200 formed can have a preferred thickness H. In detail, if the moving speed of the receiving net 122 is too large, the amount of meltblown fibers F that the receiving net 122 can receive in a unit area is too small, so that the formed three-dimensional nonwoven 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 high, the formed three-dimensional nonwoven fabric 200 cannot form a highly entangled fiber web due to insufficient amount of meltblown fibers F, thereby affecting the structural stability of the three-dimensional nonwoven fabric 200 .

In some embodiments, the vertical distance L between the roller device 130 and the collecting 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 suitable range, the three-dimensional nonwoven fabric 200 formed can also have a better thickness H. Specifically, the vertical distance L between the roller device 130 and the collecting device 120 can determine the stacking thickness of the meltblown fibers F passing therebetween, and thus can affect the thickness H of the three-dimensional nonwoven fabric 200 formed. 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 three-dimensional non-woven fabric 200 can have good bulkiness due to the mutual matching between the weight of the base fabric of the three-dimensional non-woven fabric 200 and the thickness H of the three-dimensional non-woven fabric 200 . As mentioned above, since the base fabric weight of the three-dimensional non-woven fabric 200 is related to the single-hole discharge rate of the meltblown fibers F, the thickness H of the three-dimensional non-woven fabric 200 is related to the moving speed of the receiving web 122 and the gap between the roller device 130 and the collecting device 120. is related to the vertical distance L of the melt-blown fiber F, and 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 discharge rate of the melt-blown fiber F, the moving speed of the receiving web 122, and the vertical distance L between the roller device 130 and the collecting device 120. In order 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 loft 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 listed for further explanation. The three-dimensional non-woven fabrics of each embodiment are manufactured by performing steps S10 to S40, while the comparative example is manufactured by a conventional double-roll spinning equipment with conventional steps. The detailed description of each example and comparative example is shown in Table 1.

Table I Single hole discharge rate of meltblown fibers (g/min) The moving speed of the 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, the base fabric weight, thickness, bulkiness, compression recovery rate, horizontal tensile strength and horizontal peel strength of the three-dimensional non-woven fabrics of Examples 1 to 6 and Comparative Example 1 of the present disclosure will be measured to further verify The efficacy and test results of the present disclosure are shown in Table 2 below.

Table II Base fabric weight (g/m ² ) Thickness(mm) Bulk (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 cannot be measured cannot be measured cannot be measured

It can be seen from Table 2 that the three-dimensional non-woven fabrics of Examples 1 to 6 have larger base fabric weight, thickness and better bulkiness than the three-dimensional non-woven fabric of Comparative Example 1 after the same time of manufacture. In addition, the three-dimensional non-woven fabrics of Examples 1 to 6 have good compression recovery rate, 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 rotation of the roller device allows the first part of the meltblown fibers to reach the collecting device and pass between the roller device and the collecting device together with the second part of the meltblown fibers, thereby forming a three-dimensional nonwoven fabric . By adjusting the moving speed of the receiving web of the collecting device, the single-hole discharge rate of the melt-blown fibers, and the vertical distance between the roller device and the collecting device in an appropriate range, the formed three-dimensional nonwoven fabric can be made to have a certain thickness. and good bulk.

Although the present disclosure has been disclosed as above in embodiments, it is not intended to limit the present disclosure. Anyone with ordinary knowledge in the technical field to which the present disclosure pertains may make various changes and modifications without departing from the spirit and scope of the present disclosure. Therefore, the scope of protection of this disclosure should be determined by the scope of the appended patent application.

100: Textile Equipment 110: Meltblown device 112: Spit hole 120: Collection Device 122: Undertaking Network 124: Conveying elements 126: Suction element 130: Roller device 140: Connecting elements 200: three-dimensional non-woven fabric F: Meltblown fiber F1: Part 1 F2: Part II L: distance H: Thickness S10~S40: Steps

In order to make the above and other objects, features, advantages and embodiments of the present disclosure more clearly understood, the accompanying drawings are described as follows: FIG. 1 is a schematic side view of a textile apparatus according to an embodiment of the present disclosure. FIG. 2 is a schematic side view of the textile equipment of FIG. 1 , wherein the viewing angle direction of FIG. 2 is perpendicular to the viewing angle direction of FIG. 1 . FIG. 3 shows a flow chart of manufacturing a three-dimensional non-woven fabric using the textile equipment of FIG. 1 .

Domestic storage information (please note in the order of storage institution, date and number) none Foreign deposit information (please note in the order of deposit country, institution, date and number) none

100: Textile Equipment

110: Meltblown device

112: Spit hole

120: Collection Device

122: Undertaking Network

124: Conveying elements

126: Suction element

130: Roller device

200: three-dimensional non-woven fabric

F: Meltblown fiber

F1: Part 1

F2: Part II

L: distance

H: Thickness

Claims (10)

A manufacturing method of three-dimensional non-woven fabric, comprising: Spray melt-blown fibers with a melt-blown device, wherein the single-hole discharge rate of the melt-blown fibers is between 0.01 g/min to 0.50 g/min; receiving the first portion of the meltblown fibers with a roller arrangement; receiving the second portion of the meltblown fibers with a collecting device, wherein the collecting device has a receiving web, and the receiving web moves at a rate of between 1 m/min and 5 m/min; and The first portion of the meltblown fibers is brought to the collection device by rotation of the roller arrangement. The manufacturing method of the three-dimensional nonwoven fabric according to claim 1, wherein the meltblown device has a plurality of discharge holes, and the density of the discharge holes is between 35 holes/inch to 65 holes/inch. The manufacturing method of the three-dimensional nonwoven fabric according to claim 1, wherein the melt-blown device sprays the melt-blown fibers perpendicular to the receiving surface of the collection device. The manufacturing method of the three-dimensional nonwoven fabric according to claim 1, further comprising passing the first part of the meltblown fibers 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 causing the meltblown fibers to pass between the roller device and the collecting device through the rotation of the roller device and the conveyance of the collecting device, to form the three-dimensional non-woven fabric. The method for manufacturing a three-dimensional nonwoven 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 and the tangential direction of the receiving surface of the collecting device The conveying direction is the same. The manufacturing method of the 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 manufacturing method of the 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 manufacturing method of the three-dimensional non-woven fabric according to claim 1, wherein the material of the melt-blown fiber comprises polyolefin, polyester, polyurethane and nylon, and the diameter of the melt-blown fiber in the three-dimensional non-woven fabric is between 0.2 microns to 20 microns.

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