Improved one-step method for producing plastic non-woven fabric
The present invention relates to a method for making plastic non-woven fabric, and is characterized by that it adopts high-low density polyethylene as raw material to make composite film, after the composite film is cut into net-like film, one portion of said film is used as longitudinal hot-stretching and another portion is used as transverse hot-stretching so as to respectively obtain the flat filaments with longitudinal and transverse net-like structures, and the longitudinal and transverse net-like flat filaments are oppositely stuck in the forward direction and heat-bonded so as to obtain the plastic non-woven fabric with longitudinal and transverse two-directional net-like structures.
The non-woven fabric is a new type of packing material which is made up by using crystalline high-molecular polymer as raw material to make composite film, cutting and stretching to respectively obtain longitudinal and transverse net-like structure flat filaments, then forward laminating and binding them, and has no need of spinning and weaving to obtain cloth. The non-woven fabric has the characteristics of light weight (50 g/square meter), high strength, ventilation and the like, can be made into various composite packaging materials after being compounded with paper, plastic film foamed plastic, metal foil and the like, enhances the original material with lower strength, improves the use value, is widely applied to chemical fertilizers and pesticides, particularly replaces the traditional kraft paper cement bag, can save a large amount of foreign exchange and wood, and can reduce the broken rate of cement and the packaging cost. In addition, after being compounded with the film, the composite film can also be used for seedling raising greenhouses, raincovers and the like. The application is very extensive. Because the non-woven fabric is manufactured, the non-woven fabric does not need spinning, so that the process and equipment can be greatly simplified, the area and labor of a factory building are reduced, the energy consumption and the investment are reduced, and the efficiency is 50-100 times higher than that of the traditional knitting machine.
The prior art, such as U.S. Pat. Nos. UstuAT 3, 719, one-step process for perylene 40, etc., the basic method is to melt extrude the thermoplastic and then pass it through a pair of longitudinally patterned and transversely patterned embossing rolls, respectively, each pair of embossing rolls, one is engraved with transverse concave-convex patterns or longitudinal concave-convex patterns, the other is a smooth roller, cold water is introduced into the rollers for cooling, the reticular films with the transverse concave-convex patterns and the longitudinal concave-convex patterns are respectively prepared, then respectively carrying out transverse width expanding stretching and longitudinal uniaxial stretching to prepare flat filaments with longitudinal and transverse net structures, another embodiment of the above process is to pass the extruded melt through a pair of embossing rolls engraved with an oblique angle (45) to produce a reticulated film having an angle of 45, then, the net-shaped flat wires with an angle of 45 degrees are prepared by longitudinal stretching and transverse width expanding stretching, and the net-shaped flat wires are mutually attached and overlaid and bonded into a cross non-woven fabric with an angle of 45 degrees in a 90-degree angle. Such an off-angle orthogonal nonwoven fabric is not suitable for use as a heavy packaging product because, after a tensile stress, the component force generated by the 45 ° off-angle causes the two layers of flat filaments to peel apart after bonding, which destroys the integrity of the web structure and the nonwoven fabric, and this method is generally referred to as a one-step process.
However, the above molding method has the following disadvantages:
1. the cooling process of melt embossed flat films must be very careful. The diameter of spherulites formed inside the flat film is often larger due to poor cooling, which affects the quality of the flat film. And the prior one-step process is not suitable for using polyethylene raw materials.
2. The melt embossing process is only suitable for the extrusion flat film process, but not for the tubular film process.
3. The concave-convex pattern formed by the melt embossing can not be cut thoroughly and brightly, a connected film is usually left in the concave part, although the stretching is not influenced greatly, the appearance of the stretched reticular flat filament is poor, and the most prominent problem is that the longitudinal and transverse grid structures and the strength of the non-woven fabric prepared by the method are not consistent, so that the use value of the non-woven fabric is influenced.
At present, high-low density polyethylene is adopted as a raw material to prepare a two-layer coextruded composite film with high and low melting points, the high-low density polyethylene has similar structural characteristics and better chemical affinity, so the prepared composite film has better adhesive force, and due to the difference of the melting points, for example, the low density polyethylene can be melted at 20-30 ℃ lower than the melting point of the high density polyethylene and can be instantly solidified when cooled, thereby solving the problem of bonding of longitudinal and transverse net-shaped flat filaments. In addition, the high-density polyethylene is used as a main raw material, so that the high-density polyethylene has better tensile strength.
The existing two-step method is to use only the same composite film, firstly to cut longitudinally and stretch longitudinally and uniaxially to obtain a reticular flat filament, secondly to use the stretched reticular flat filament as warp and weft base materials respectively, to carry out laying and laminating by a warp and weft orthogonal combiner, and to obtain a non-woven fabric by heat bonding, the method is invented and patented by the Japanese Polymer processing research institute, the invention is successfully made in U.S. Pat. No. Uusat 4, 052, 242, which opens a new way for non-woven fabric forming process using high density polyethylene as raw material, this method is a method for manufacturing "Rishiwalff cut cloth" used by New Japan Petroleum chemical Co, the two-step forming method has the advantages that the heat bonding of the high-low density polyethylene composite film is adopted, and the non-woven fabric with the warp-weft grid structure and the consistent strength can be manufactured.
However, the existing two-step method still has the following defects:
1. since the mesh-like flat wires in the warp and weft directions are thinned by drawing, they are easily disturbed during the cutting and conveying in the weft direction, the laying and the bonding, and the simultaneous alignment of the warp and weft directions is large, so that it is difficult to perform the high-speed combination and laying.
2. The warp and weft combined machine has complicated structure, and the cutting and conveying in weft direction are completed through twisting viscous liquid and floating conveying belt or mechanical method to make vertical crossing and spreading, continuous conveying to adhesive roller for hot adhesion to produce non-woven plastic fabric, washing viscous liquid and sucking to dry.
The invention aims to utilize the characteristics of high-speed overlaying layers of the non-woven fabric prepared by the existing one-step method of melting embossing transverse spreading stretching and longitudinal uniaxial stretching and also utilize the advantages of heat bonding of a composite film with high and low melting points in a two-step method, thereby overcoming the defects of inconsistent structure and strength of a longitude and latitude grid of the plastic non-woven fabric in the existing one-step method and avoiding using a longitude and latitude right-angle orthogonal combiner with a more complex structure.
The basic method of the invention is as follows:
1. the composite film is prepared by adopting high-density polyethylene (with the melting point of about 137 ℃) as a main raw material and low-density polyethylene (with the melting point of 105-110 ℃) as an adhesive film, and has the difference of high and low melting points, so that the defect that the cost is high and the number of steps is large due to the use of a chemical adhesive or a hot melt adhesive in an adhesive process can be overcome in the adhesive process.
2. Transverse spreading stretching and longitudinal uniaxial stretching are utilized, then longitudinal and transverse net-shaped flat wires are continuously attached in one step in a forward direction, the low-melting-point film layer is firstly melted under the heating condition to enable the warp net wires and the weft net wires to be melted into a whole, and then the warp net wires and the weft net wires are bonded to form the plastic non-woven fabric after cooling and solidification.
3. The longitudinally and transversely stretched net-like film is cut by the same cutting device and cutter, so the patterns of the longitudinally and transversely stretched net-like structure are completely the same, and the transversely stretched net-like film and the longitudinally stretched net-like film can be oriented only by uniaxial stretching, so that the strength of the produced non-woven fabric in both warp and weft directions is consistent with the grid patterns, and the implementation method is as follows: the net-shaped film for transverse stretching is only cut into a piece of net-shaped film with a certain width after longitudinal cutting. This piece of cut net film was cut. The ninety-degree angle is rotated to change direction and the fiber is conveyed into the expander, so that the longitudinal direction and the transverse direction are stretched only by uniaxial orientation.
4. Because the non-stretched net-shaped cutting film is subjected to ninety-degree direction change after being cut into blocks, the net-shaped cutting film is stiff and smooth, has small breadth, is not easy to disorder, is more convenient and has higher efficiency compared with a two-step method in which a stretched light and thin net-shaped flat wire is used. This provides advantages for high speed production.
5. The transverse netted flat filament is sandwiched with the stretched longitudinal netted flat filament, and the longitudinal netted flat filament is then laminated and adhered in the same running direction, and the laminated and adhered film is heated to melt the low melting point film, and the low melting point film is finally pressed, cooled, solidified and adhered to form the non-woven plastic fabric.
The invention is mainly characterized in that the warp and weft combining machine with complex structure in the two-step method is avoided, and the high-speed forward laminating, laminating and bonding of the warp net in the tension state, which enables the weft net to be orthogonal to the weft net in a right angle under the clamping state in the one-step method, are exerted, so that the regularity and consistency of the grid structure are maintained. Thirdly, the longitudinal and transverse stretching of the invention only uses the same composite film and cutting patterns with the same structure, so the product has consistent longitudinal and transverse strength and consistent grid structure, thus the invention has practical value.
In order to achieve the above objects, the present invention is realized by the following steps:
1. raw materials are selected:
the high-density polyethylene (HDPE) can be made from Liaoyang chemical plant of China, and has a mark of GF7750 or imported raw materials, such as 5000S produced in Japan, and GF7750 produced in West Germany, and the technical parameters of several raw materials are as follows: (see later) HDPE materials are required to have a relatively high molecular weight (around 10 ten thousand), a relatively narrow molecular weight distribution, a relatively small density gradient and a relatively high degree of crystallinity.
The LDPE can be generally made of domestic low density polyethylene, and has a melting point of 105-110 ℃, MI of 3-5, and the melt viscosity of the high low density polyethylene is close to that of the low density polyethylene.
2. Film preparation:
(1) in order to prepare the two-layer coextruded composite film, a reasonable machine head structure and a temperature control system are selected in addition to proper raw materials.
(2) The composite tubular film and the composite flat film are prepared by a co-extrusion blow molding process or an extrusion flat film process.
(3) The tubular film is cooled by primary air ring and then water ring, and the flat film is directly cooled by water, so that the cooling effect and the film quality are improved.
3. Cutting the mixture to obtain the finished product,
both the tubular film and the flat film can be cut by the barbed cutting tool invented by the inventor.
4. Cutting and reversing the transverse stretching net membrane block:
one of the cut net-shaped films is firstly cut into net-shaped film blocks with a specified width along the transverse direction by an electric heating cutter, and then the net-shaped film blocks enter a transverse width expanding stretcher through a direction changing mechanism.
The transverse net-like film pieces can be cut into pieces and reversed by cutting the net-like film pieces into pieces at intervals of 160 to 180mm, which are longitudinally stretched in the transverse direction. And stacked to a predetermined height (with the low melting point facing downward) and then placed in a sheet feeding tank at the front end of a tenter while changing the direction, and the web-like film block having changed the direction is fed one by a sheet feeding machine into a nip of a holding belt of a tenter and is rapidly held and fed into a preheating zone, which is called an intermittent sheet feeding method. Is simple and easy to operate.
The second is to continuously feed the net film cut into longitudinal patterns into a rotary electric heating cutting tool, cut into film blocks with the interval of 160-180 mm, then convey the film blocks to the tail end by a conveyer belt, slide the film blocks into a chute conveying along the ninety-degree reversing direction by an inclined plate, then be quickly pressed and held by a circulating pressing belt, enter clips of the clip belts at two sides of a width expander, be clamped, and then enter a preheating section, namely a continuous sheet feeding method.
5. In order to make the net-like structure of the longitudinally and transversely stretched net-like film completely identical, the present invention recommends the following two methods: the first method is a tubular film method, the tubular film is folded and flattened into a double-layer film, the double-layer film with certain patterns is cut into a double-layer reticular film with certain patterns at one time, then the double-layer reticular film is divided into an upper layer and a lower layer, the upper layer is used for transverse block cutting and reversing and transverse spreading stretching, and the lower layer is used for longitudinal uniaxial stretching.
The second method is a flat film method, which comprises extruding and cooling with a set of extruders (two extruders) under stable conditions, cold cutting, winding into rolls, and using the two rolls of the web film as transverse and longitudinal stretched web films, respectively. Or two groups of extruders (two each) are used for transverse stretching and longitudinal stretching, so that the two groups of extrusion speeds, the pattern structure of the cutting tool and the rotating speed of the cutting tool are completely consistent, and two groups of reticular films with consistent patterns can be prepared.
The tubular film method can obtain complete consistency of the pattern structure.
6. In order to achieve the uniformity of the stretching ratio and the strength of the longitudinal and transverse net-shaped flat filaments, the transverse width expanding stretching ratio is fixed, and the strength of the longitudinal and transverse stretched net-shaped flat filaments after stretching can be uniform by adjusting the longitudinal stretching ratio.
7. In order to convert the cutting pattern of the web film as the transverse stretching from the longitudinal cutting pattern to the transverse cutting pattern, it is necessary to cut the film having the longitudinal cutting pattern in the transverse direction into a web film having a width of 160 to 180mm, and then to perform a ninety-degree direction change to convert the cutting pattern to be aligned in the transverse direction, so that both the longitudinal uniaxial stretching and the transverse tenter stretching are performed only uniaxially.
Fig. 1 and 2 are schematic views of the cut-off and reversal transport of transverse wire blocks:
1. the cutting machine comprises a cutting machine body, a cutting lining roller, a reverse stopping ratchet wheel, a guide roller, a clamping conveyor belt, a pressing roller, a cutter, a guide clamping roller, a transverse conveyor belt, a guide roller, a clamp conveyor belt, a guide roller, a clamp conveyor belt, a lower guide roller, a clamping conveyor belt, an upper guide roller, a preheating section, a width expanding section, a hot setting section, a transverse net flat wire, a.
FIGS. 3 and 4 are schematic views of an intermittent sheet adding machine:
27. conveying belt 28, feeding sheet pushing wheel 29, pushing rod 30, half-circumference gear 31, pushing rack tooth 32, pushing slide rod 33, tensioning spring 34, sliding groove 35, stacking groove 36, reversed net block 37 and lifting floating roller.
FIG. 5 is a schematic of an example one (tube-membrane process) process flow:
43a43b, extruding, 44, forming a film by a circular machine head, 45, cooling, 46, folding into a double-layer composite film, 47, cutting the double layers at one time, 48, cutting the two sides, conveying in a reversing way at an angle of 49 and 90 degrees, 50, transversely cutting into blocks, reversing at an angle of 51 and 90 degrees, 52, stretching in a warp direction and a single shaft, 53, stretching in a transverse spreading manner, 54, primarily bonding in a longitudinal and transverse mode, 55, thermally bonding, 56, cooling, 57, trimming, 58 and obtaining a non-woven fabric finished product.
FIG. 6 is a schematic of an example two (flat membrane process) process flow:
59a59b, extrusion, 60, forming film by a clothes rack-type machine head, 61, cooling, 62, cutting 63, longitudinally stretching, 64 dicing, conveying in a direction change at an angle of 65 and 90 degrees, 66, transversely spreading and stretching, 67, latitudinal reticular flat yarns, 68, longitudinally reticular flat yarns, 69, continuously laminating, 70, thermal bonding, 71, cooling, 72, trimming, 73, and obtaining a non-woven fabric finished product.
The net-shaped film 1 cut into longitudinal patterns is drawn and unreeled by a drawing roller 2, enters an alloy steel cutter 6 through a conveyer belt 3 and is heated by an electric heater 7, the alloy steel cutter is heated by the electric heater 7, when the net-shaped film passes through the cutter, the cutter rotates to the central point (right position) of cutting from a rotating frame 5, the net-shaped film is heated, melted and cut between a backing roller 8 and a cutter edge, and the cut net-shaped film blocks are separated from a net-shaped film roll by the drawing of a pressing conveying roller 10. The cut pieces of the net-like membrane are carried to the end of the conveyor belt by the conveyor belt 14 and slide into the transverse conveyor groove 16 by the inclined plate 15. The transverse conveying belt 18 is arranged in the conveying groove, when the net membrane block slides into the transverse conveying groove by the inclined plate, the net membrane block is conveyed out of the transverse groove by the conveying belt 18, after one end of the net membrane block is output out of the transverse groove, the net membrane block is clamped by a clamping conveying belt 25 and conveyed to the transverse expanding machine, the transverse membrane block is immediately clamped by clamps on clamping belts 22 of opening openings on rails on two sides of the expanding machine, and then the transverse membrane block sequentially enters a preheating section 38, an expanding and stretching section 39 and a heat setting section 40, so that transversely stretched net-shaped flat filaments 41 are manufactured.
The intermittent feeding method can be carried out as shown in fig. 3 and 4, the cutting of the reticular membrane is completely the same as the method, only the reticular membrane of the cutting block is piled up to a certain height and then is sent into a piling groove 36, the reticular membrane block 35 is sent into the conveying belt 27 and the floating roller 37 one by the back and forth pushing of the pushing rod 29 and the pushing wheel 28 with the anti-reverse ratchet wheel, the position is adjusted by automatically swinging up and down along with the increase and decrease of the reticular membrane block in the piling groove, so that the effective reciprocating motion of the reticular membrane block entering the conveying belt 27 and the pushing rod 29 is achieved by the periodic reciprocating motion of the teeth 31 of the semi-circle gear 30 and the sliding rod 32 tensioning the spring 33, and the reticular membrane blocks are then sent to the expanding machine one by one.
The middle of the two clamp belts 23 and the two sides of the reticular block are respectively clamped by the clamps 22 on the left and the right clamp belts 23 and enter a preheating section 38, an expanding and stretching section 39 and a heat setting section 40, and the transversely stretched reticular flat filament 41 is prepared.
The following are examples of embodiments of the invention:
example one: the one-step forming method for cutting and making the fiber by the tubular composite membrane comprises the following steps:
as shown in FIG. 5, high-density polyethylene (HDPE) and low-density polyethylene (LDPE) are fed into two extruders 43a and 43b, respectively, the plastic is melted under external heating and the rotation friction of a screw, extruded into a ring-shaped co-extruder head 44 and extruded into a tubular composite film, the tubular composite film is cooled 45 and folded into a double-layer film 46 by a nip roll, cut 47 once and then split into upper and lower composite films 48 on both sides, the lower cut net film is subjected to longitudinal uniaxial hot stretching 52 in the extrusion direction to obtain a longitudinally stretched net-shaped flat filament, the upper cut net film is subjected to 90 DEG reversing conveyance by a 45 DEG guide roll 49 and then cut 50 DEG in the horizontal direction to obtain a net-shaped flat filament with equal width, and then conveyed 51 in a 90 DEG reversing conveyance direction by a grooved conveyor belt to enter a transverse spreading stretcher 53 to obtain a transverse-patterned net-shaped flat filament, then the fiber enters a heat setting section to be attached with longitudinally stretched netted flat filaments entering from the lower part along the advancing direction, the longitudinal and transverse nets are orthogonal at right angles, the mutually attached low-melting-point film layers are heated and melted into a whole, the fiber is cooled 56 by a cooling pressing roller to enable the longitudinal and transverse directions to be primarily bonded into a non-woven fabric, the non-woven fabric leaves an expander and needs to be thermally bonded 55 again, cooled 56 and trimmed 57 to be rolled into a plastic non-woven fabric 58, the weight of each square meter of the non-woven fabric is about 50 g, the width is 1100mm, and the thickness is 0.06-0.08 mm.
The density of the longitude and latitude is 6 multiplied by 6 pieces/inch square.
EXAMPLE two, composite Flat Membrane Process
High and low density polyethylene is fed into two extruders 59a and 59b, respectively, the extruded melt is fed into a wide-width hanger-type co-extruder head 60, the extruded flat film melt is immediately fed into a cooling water tank to be cooled 61 to obtain a composite flat film, then the composite flat film is cut 62 in longitudinal patterns, the cut film with a net structure is made into a roll, and the roll is fed to longitudinal and transverse stretching machines, respectively. A roll of the cut web is unwound from a longitudinally stretched unwinding spool, and is heated to 95-110 ℃ in a pre-heating roll before stretching, and then is subjected to hot stretching 66, so that the longitudinally stretched web becomes extended net-like flat filaments. And is led into the heat setting section of the expanding machine, meanwhile, the other roll of the reticular membrane is sent to a reversing and cutting conveyor, enters a transverse cutting machine for cutting 64, the cut reticular membrane is conveyed to the tail end of the cutting machine and falls into a reversing conveying groove, is reversed at an angle of 90 degrees by a reversing conveying belt, rapidly leaves the reversing conveying groove, enters the beginning end of a clamp belt of the transverse expanding machine to be immediately clamped by a clamp, then transversely expands and stretches to a certain multiple, enters the heat setting section of the expanding machine, enters the longitudinal reticular flat wire of the heat setting section of the expanding machine from the lower part, simultaneously enters the heat setting section, is subjected to heat setting, melts the low-melting-point membrane of the longitudinal and transverse webs, is relatively attached, is solidified into plastic non-woven fabric through a pair of cooling press rollers and cooling, then leaves the expanding machine to enter the heat sealing roller for reheating bonding, cooling, trimming and rolling to obtain the finished product of the plastic non-woven fabric.
It is also possible to produce a cut web with a uniform pattern by two sets of extruders (four sets), and then to produce a nonwoven fabric in one step by stretching it longitudinally and transversely in the manner described above, taking care that the web pattern structure of the webs produced by the two sets of extruders is uniform.
Melting point of trade mark melt index density
GF 77500.5-0.40.940-0.950137 Liaoyang chemical plant in China
5000S 0.750.955135 Japan
GF77500.50.95137 Cshdoherty power amplifier