Method for manufacturing polyester filament spun-bonded non-woven fabric

Abstract

A method for manufacturing polyester filament spun-bonded non-woven fabric, comprising, i) drying respectively some polyester chips and black color masterbatch; ii) conveying the dried polyester chips and the dried black color masterbatch to a screw extruder for being melted and compressed into a viscous melt, and making the melt pass through a melt filter to remove impurities; iii) evenly distributing the filtered melt into each metering pump through a spinning manifold, cooling the output melt into filaments, drawing the filaments by airflow and the drawn filaments laying into fiber web, and preliminarily ironing and flattening the fiber web by a needle to obtain a fiber web-reinforced non-woven fabric; iv) winding the non-woven fabric by a winder and then shaping the non-woven fabric by a hot mill to obtain a polyester filament spun-bonded non-woven fabric. The polyester filament spun-bonded non-woven fabric exhibits superior tensile strength are excellent.

Claims

1. A method for manufacturing polyester filament spun-bonded non-woven fabric, wherein the polyester filament spun-bonded non-woven fabric is prepared by the following steps: i) preparation of raw material: drying some polyester chips and black color masterbatch respectively, wherein the polyester chips account for 95-98% and the black masterbatch accounts for 2-5%; ii) conveying the dried polyester chips and the dried black color masterbatch to a screw extruder for being melted and compressed into a viscous melt, and making the melt pass through a melt filter to remove impurities and obtain filtered melt; iii) evenly distributing the filtered melt into each metering pump through a spinning manifold, wherein the spinning manifold maintains 297 C. to 299 C., the metering pump outputs the melt at 9.08-9.11 m/min, cooling the output melt into filaments under the action of cooling air; drawing the filaments by airflow to obtain drawn filaments and laying the drawn filaments into fiber web; and preliminarily ironing and flattening the fiber webby a pre-pressing roller and then repeatedly punching the fiber web by a needle with a groove on the edge to obtain a fiber web-reinforced non-woven fabric; iv) winding the non-woven fabric obtained through the punching process in step by a winder and then shaping the non-woven fabric by a hot mill to obtain the polyester filament spun-bonded non-woven fabric; wherein a revolving speed of the screw extruder in step ii) is 40-42 r/min, and temperature conditions required for melting and compressing are as follows: the screw extruder is divided into a cold zone, zone 1, zone 2, zone 3, zone 4, zone 5, zone 6 and zone 7, wherein the cold zone is 46 to 48 C., zone 1 is 280 to 290 C., zone 2 is 282 to 292 C., zone 3 is 284 to 294 C., zone 4 is 286 to 296 C., zone 5 is 288 to 298 C., zone 6 is 289 to 299 C. and zone 7 is 287 to 297 C. respectively.

2. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 1, wherein the laying process in step iii) is as follows: dispersing the drawn filaments by a swinger and then making the drawn filaments adsorb onto a transmission mesh, wherein the swinging frequency is 500 to 600 times/min, and the pre-pressing roller is 144 to 146 C.

3. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 2, wherein the punching process in step iii) is as follows: feeding the fiber web that has been preliminarily ironed and flattened by the pre-pressing roller into a needling machine and punching the fiber web by a plurality of felting needles with grooves, making the fiber web moves up and down and compressing the fiber web when approaching; when the grooves reach a certain depth, the felting needles start to rise and the displaced fibers are separated from the grooves and left in the fiber web in a vertical state, which makes the compression generated by the fiber web non-recoverable; after punching each square centimeter of the fiber web for dozens or hundreds of times, making a certain number of fibers punch into the fiber web; thus obtaining the fiber web-reinforced non-woven fabric with the increasing friction force between fibers in the fiber web.

4. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 3, wherein three needling machines are provided in step iii), wherein the first needling machine is used for preliminarily connecting the non-woven fabric, the second needling machine is used for forcibly locking the non-woven fabric, and the third needling machine is used for repairing and flattening the non-woven fabric, wherein the needle types are M222 and C222.

5. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 1, characterized in that a speed of the winder is 10.1-10.3 m/min in step iv.

6. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 1, characterized in that the shaping temperature of the hot mill in step iv) is as follows: an upper roller is 240 to 245 C., and a lower roller is 230 to 235 C.

7. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 1, characterized in that a winding speed of the hot mill is 20-25 m/min in step iv).

8. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 1, characterized in that the drawing pressure of the airflow drawing process in step iii) is 5.2 to 5.6 bar.

9. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 1, characterized in that side air blasting of the filament cooling process in step iii) requires a temperature of 23 to 25 C., a humidity of 85-87%, and a pressure of 130-140 pa.

10. The method for manufacturing polyester filament spun-bonded non-woven fabric according to claim 1, characterized in that the drying process of the polyester chips in step i) is as follows: sending wet chips to a chip hopper by a conveying system for use in a crystallizer; making the wet chips fall into a pulsating bed under gravity through a slide damper of the chip hopper; the crystal chips remain in the crystallizer for 15 to 20 min with a crystallization temperature of 173 to 176 C. and a rotating speed of crystallization fan of 78 r/min; the crystallized chips are continuously and uniformly fed into a primary drying tower, and remain in the primary drying tower for about 4 to 6 hours with a drying temperature of 164 to 166 C. and a dew-point temperature of 89 to 91 C.; for the black color masterbatch, the drying temperature is 130 C. and the drying time is 8 hours.

Description

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(1) The invention relates to a polyester filament spun-bonded non-woven fabric for automobile seats, comprising the following raw materials in percentage by weight: 95-98% of polyester chips and 2-5% of black color masterbatch.

Example 1

(2) The invention relates to a polyester filament spun-bonded non-woven fabric for automobile seats, which comprises the following raw materials in percentage by weight: 98% of polyester chips and 2% of black color masterbatch. The polyester filament spun-bonded non-woven fabric is prepared by the following method:

(3) i) Preparation of raw materials, i.e., drying of polyester chips: the wet polyester chips are sent to a chip hopper by a conveying system for use in a crystallizer; the wet chips fall into a pulsating bed under gravity through a slide damper of the chip hopper; the crystal chips remain in the crystallizer for 15 to 20 min with a crystallization temperature of 173 to 176 C. and a rotating speed of crystallization fan of 78 r/min; the crystallized chips are continuously and uniformly fed into a primary drying tower, and remain in the primary drying tower for about 4 to 6 hours with a drying temperature of 164 to 166 C. and a dew-point temperature of 89 to 91 C.

(4) Drying of black color masterbatch: the black color masterbatch is dried 8 hours in a dryer with a drying temperature of 130 C.

(5) ii) The dried polyester chips and the dried black color masterbatch are conveyed to a screw extruder for being melted and compressed into a viscous melt, and the melt is allowed to pass through a melt filter to remove impurities; wherein the revolving speed of the screw extruder is 40-42 r/min, and the temperature conditions required for melting and compressing are as follows: the screw extruder is divided into a cold zone, zone 1, zone 2, zone 3, zone 4, zone 5, zone 6 and zone 7, wherein the cold zone is 46 to 48 C., zone 1 is 280 to 290 C., zone 2 is 282 to 292 C., zone 3 is 284 to 294 C., zone 4 is 286 to 296 C., zone 5 is 288 to 298 C., zone 6 is 289 to 299 C. and zone 7 is 287 to 297 C. respectively.

(6) iii) The filtered melt is evenly distributed into each metering pump through a spinning manifold, the metering pump outputs the melt at 9.08-9.11 m/min, and the output melt is cooled into filaments under the action of side air blasting; the filaments are drawn by airflow and laid into fiber web; the fiber web is repeatedly punched by a needle with a groove on the edge to obtain a fiber web-reinforced non-woven fabric; wherein the drawing pressure in the airflow drawing process is 5.2 to 5.6 bar;

(7) wherein, specific process parameters of the spinning manifold are provided in Table 1.

(8) TABLE-US-00001 TABLE 1 Specific process parameters of spinning manifold Process item Unit Scope Manifold temperature C. 297-299

(9) The laying into fiber web process is as follows: the drawn filaments are dispersed by a swinger and adsorbed onto a transmission mesh and compressed by a pre-pressing roller; wherein the swinging frequency of the swinger is 500 to 600 times/min, and the pre-pressing roller is 144 to 146 C.

(10) The side air blasting of the filament cooling process requires a temperature of 23 to 25 C., a humidity of 85-87%, and a pressure of 130-140 pa.

(11) The specific punching process is as follows: the fiber web that has been preliminarily ironed and flattened by the pre-pressing roller is fed into a needling machine and punched by a plurality of felting needles with grooves, so that the fiber web moves up and down and is compressed when approaching; when the felting needles reach a certain depth, the felting needles start to rise; since the felting needles move clockwise, the displaced fibers are separated from the grooves and left in the fiber web in a vertical state, just like many fibers are pinned into the fiber web, which makes the compression generated by the fiber web non-recoverable; after each square centimeter of the fiber web is punctured for dozens or hundreds of times, a certain number of fibers are punctured into the fiber web; thus the fiber web-reinforced non-woven fabric is obtained with the increasing friction force between fibers in the fiber web and the increasing density and strength of the fiber web. In this process, three needling machines are provided. The first needling machine is used for preliminarily connecting the non-woven fabric, the second needling machine is used for forcibly locking the non-woven fabric, and the third needling machine is used for repairing and flattening the non-woven fabric, wherein the needle types are M222 and C222. See Table 2 for specific needling parameters.

(12) TABLE-US-00002 TABLE 2 Needling parameters Process item Unit Scope {circle around (1)} Needling density c/cm.sup.2 26-28 {circle around (1)} Needling density mm 9.3-9.5 {circle around (2)} Needling density c/cm.sup.2 34-36 {circle around (2)} Needling density mm 3.49-3.52 {circle around (3)} Needling density c/cm.sup.2 2.5-2.6 {circle around (3)} Needling density mm 40-42

(13) iv) The non-woven fabric obtained through the punching process in step 3) is winded by a winder and then shaped by a hot mill to obtain a polyester filament spun-bonded non-woven fabric; wherein the speed of the winder is 10.1-10.3 m/min. The shaping temperature of the hot mill is as follows: the upper roller is 240 to 245 C., and the lower roller is 230 to 235 C.

Example 2

(14) The invention relates to a polyester filament spun-bonded non-woven fabric for automobile seats, which comprises the following raw materials in percentage by weight: 95% of polyester chips and 5% of black color masterbatch; and the preparation method of the polyester filament spun-bonded non-woven fabric is the same as that of example 1.

Test Example

(15) Tensile strength, heat resistance and aging resistance of the polyester filament spun-bonded non-woven fabric for automobile seats of the present invention are tested according to American standards ASTM D5034 and ASTM D5733. The results are provided in Table 3.

(16) TABLE-US-00003 TABLE 3 Performance test results of polyester filament spun- bonded non-woven fabric of the present invention Polypropylene staple fiber needle-punched Item Example 1 Example 2 non-woven fabric Test standard Tensile Axial: 700N; Axial: 710N; Axial: 500N ASTM D5034 strength Lateral: 600N Lateral: 610N Lateral: 400N Heat Melting point: Melting point: Melting point: resistance 168-174 C. 168-174 C. 265 C. Aging Strong Strong Strong resistance

(17) The above embodiments are only preferred embodiments of the invention which are not used to limit the invention. Any modification, equivalent replacement and improvement made within the range of the spirit and rule of the invention shall be incorporated into the protection range of the invention.