Spunlace non-woven production process
The production process of spunlace non-woven fabrics, our knowledge of fabrics is getting more and more poor, especially for many types of fabrics, everyone must not know spunlace non-woven fabrics, I believe that many people who are engaged in fabrics Friends of processing and production are familiar with spunlace non-woven fabrics. Most fabrics are made of densely intertwined fibers, and spunlace non-woven fabrics are no exception, but they are composed of multiple layers of fibers. And it contains a wide range of fibers, and the raw materials of its fibers are diverse. The following editor will introduce the production process of spunlace non-woven fabrics.
I. Spunlace nonwoven process:
A. Fiber raw material → opening and mixing → carding → cross-laying → drafting → → pre-wetting → positive and negative water Thorn→finishing→drying→winding ↑↑water treatment cycle
B. Fiber raw material→opening and mixing→carding messy web→→pre-wetting→positive and negative spunlace→finishing→drying → Winding ↑↑ Different web-forming methods of water treatment cycle affect the vertical and horizontal strength ratio of the final product. Process A adjusts the vertical and horizontal strength ratio of the fiber web better, and is suitable for the production of spunlace synthetic leather base fabric; Process B is suitable for Production of spunlace sanitary materials.
The formed fiber web is sent to the hydroentanglement machine for reinforcement, and the first is pre-humidification treatment.
The purpose of pre-wetting is to compact the fluffy fiber web and remove the air in the fiber web, so that the fiber web can effectively absorb the energy of the water jet after entering the spunlace zone, so as to strengthen the fiber entanglement effect.
Common pre-wetting methods:
<>Double mesh clamping type
<>Perforated roller and mesh conveying curtain clamping type
The pre-wetted fiber web enters the spunlace area, and the water jets of the water jetting plate of the spunlace head spray multiple fine water jets, which are shot vertically to the fiber web. The water jet displaces a part of the surface fibers in the fiber web, including the vertical movement to the opposite side of the fiber web. reverse side. Under the dual action of the direct impact of the water jet and the rebound of the water flow, the fibers in the fiber web are displaced, interspersed, entangled, and cohesive, forming numerous flexible entanglement points, thereby strengthening the fiber web.
The vertical injection of water jets on the web can prevent damage to the web structure and maximize the use of the energy of the water jets, which is beneficial to improve the performance of spunlace nonwovens.
The spunlace reinforcement methods mainly include three forms of spunlace reinforcement with flat mesh, drum spunlace reinforcement, and spunlace reinforcement with a combination of drum and flat mesh.
The weave structure of the support screen and the appearance and structure effect of the fiber web In the drum spunlace reinforcement process, the spunlace heads are arranged along the circumference of the drum, the fiber web is adsorbed on the drum, and the spunlace head is ejected. jet of water jet. The fiber web is adsorbed on the drum, and there is no deviation phenomenon, which is conducive to high-speed production. At the same time, the fiber web moves on a curved surface in the spunlace area, and the spunlace surface is relaxed and the reverse side is compressed, which is conducive to the penetration of water jets and effectively. tangled fibers.
The drum is a metal cylinder perforated structure with a built-in dewatering device, which has a good rebound effect on the water flow compared with the flat net spunlace reinforced support net curtain.
(3) Spunlace reinforcement combined with rotary drum and flat mesh In the spunlace reinforcement process, the combined use of flat type and rotary drum type can enhance strengths and avoid weaknesses, and give play to their respective advantages. The second stage is drum spunlace, and the third stage is flat mesh spunlace.
(4) The number of spunlace heads and the number of spunlace heads commonly used in the hydraulic spunlace reinforcement process are 7~12, and the commonly used water pressure is 60~250Bar, depending on the quality of the fiber mesh per unit area and the production speed etc., the spunlace pressure setting is usually low→high→low.
(5) Structural analysis of water jet According to fluid mechanics, water is ejected from the water jet orifice, which can be called a non-submerged free turbulent jet. After the water jet is ejected from the water jet holes, due to the lateral pulsation of the turbulent jet and the frictional resistance of the air convection beam, the water jet is gradually transformed from a clustered jet to a dispersed water droplet.
The purpose of dehydration is to remove the retained water in the fiber web in time, so as not to affect the entanglement effect of the next spunlace. When the amount of water retained in the fiber web is large, it will cause the dispersion of water jet energy, which is not conducive to fiber entanglement. After the spunlace process is completed, the moisture in the fiber web is reduced to a minimum, which is beneficial to reduce the drying energy consumption.
V. Water treatment and recycling
The water consumption of the spunlace nonwoven production process is very large. When the output reaches 5 tons/day, the water consumption is about 150m3~160m3 per hour. In order to save water and reduce production costs, about 95% of the water must be recycled after water treatment.
(1) Water requirements for spunlace nonwoven process <>When the content of suspended solids is high, the service life of filter bags and filter elements will be shortened.
<>Organic substances in dissolved or colloidal dispersion state easily make water cloudy and produce color. These substances are easily deposited on the wall of the water spray holes and adhere to the fibers, thereby affecting the final whiteness of the product.
<>The slurry mass formed by microorganisms, after being transported by the high-pressure water pump, will quickly block the water spray holes, resulting in a sudden increase in the pressure of the spunlace head, and in severe cases it will cause shutdown.
<>Inorganic salts dissolved in water, whether it is an anion or a cation, have an impact on the spunlace process. Calcium and magnesium ions produce fouling in pipelines and equipment, and iron, manganese, copper and other ions are prone to produce colored substances. For the production of white sanitary materials, their content should be strictly controlled. When the chloride ion content is large, it is easy to cause equipment corrosion.
The combination of various fibers and multi-layer fibers is a spunlace non-woven fabric, but this cannot be officially called a spunlace non-woven fabric, the reason why it is called Non-woven is because it is not woven, but the process of weaving is turned into automatic jetting. The process of jetting the various fibers together strengthens the fabric's durability, which in turn increases the fabric's quality.
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