Abstract:
The invention relates to a swiftly breakable and totally degradable non-woven spunlace and its fabrication methods and production line. It is composed of 35-50% zigzagging flat viscose and 65-50% wood pulp. It enjoys the following strengths: excellent breaking performance; total degradation of non-woven fiber upon breaking and avoidance of second environmental protection; great play of material features due to pre-treatment of raw materials and good strength of non-woven cloth under the dry and humid status.

Description:
TECHNICAL FIELD 
       [0001]    US2013004552A1 is named after “water dispersible non-woven fabric materials”. Non-woven multi-layered fabric materials which include two external layers made of continuous filaments of a water soluble or water dispersible polymer having an internal layer of a water-absorbent, flushable material are provided. The continuous filament of non-woven fabric materials has water content of about less than 10% (weight). Characterized in that: it also includes the dry substance with following composition: household or individual nursing articles; medical substance and/or one or several mini capsules containing slow releasing substance. Characterized in that: The water-absorbent materials include cellulose pulp fiber. Characterized in that: non-woven fabric materials are immersed into the substance with hydrophobic property. It is a derivative of fatty acid in the organic solvent (not water). It includes one upper layer of continuous filaments of a water-soluble or water dispersible polymer, one lower layer of continuous filaments of a water-soluble or water dispersible polymer. The length of said cellulose pulp fiber changes within a range of about less than 2.5 mm. The non-woven fabric materials of a water-soluble or water dispersible polymer are selected from the following groups: PVA, carboxymethylcellulose, guar gum, alginate, starch, water dispersible copolyester and their mixture. 
         [0002]    The non-woven fabric material has a diameter of 0.5-6.7 dtex in the continuous filament. 
         [0003]    It is adopted to manufacture non-woven fabric materials and includes the following procedure: 
         [0004]    a) Fabricate woven and adhesive filament out of first layer of water soluble or water dispersible polymer; 
         [0005]    b) Implement placing; fabricate one layer of water-absorbent fiber on the layer in a); 
         [0006]    c) The other layer of woven and adhesive filament; 
         [0007]    d) Provide one or numerous connection processes for bonding single layer and/or multi-layer materials under the dry status. It is characterized in that: adopt such a method in one or numerous bonding procedures; therefore, the non-woven fabric materials have a water content of about less than 10% of total weight; 
         [0008]    e) Procedure d) of immersed non-woven fabric materials is selected from the following categories: household articles, dry objects for individual nursing, medical articles with dry substance as the topic and slow-release microcapsule of one or numerous such substances; 
         [0009]    f) Non-woven fabric materials immersed in the organic solvent (not water) of fatty acid&#39;s derivative. It consists of the combination of one or numerous procedures or one or numerous connection processes before pre-consolidation of single layer in the continuous filament and/or multi-layer materials. The production line of said woven and adhesive filament may share an independent production line with the said non-woven fabric materials; as for the said single-layer and/or multi-layer non-woven fabric materials, the combination or pre-consolidation is realized by rolling stratified materials in two rollers. The said bonding single-layer and/or multi-layer materials include the dry network process, chemical bonding process and needling. It includes single-layer and/or previous non-woven fabric materials added in one or numerous procedures; the said one or numerous connection processes are selected from one or numerous substances: household articles, individual nursing articles, medical articles, super absorbent fiber, super absorbent polymer powder and additional substance. 
         [0010]    The invention relates to a swiftly breakable and totally degradable non-woven spunlace and its fabrication methods and production line. It belongs to the manufacturing field of breakable and degradable non-woven cloth. 
       BACKGROUND ART 
       [0011]    The defects include: 
         [0012]    1. Numerous layers of non-woven cloth suffer from poor breaking property; 
         [0013]    2. The constitution of materials fails to realize total degradation and leads to second environmental pollution; 
         [0014]    3. Since the raw materials are not pre-treated, the features can not be realized so that necessary non-woven cloth suffers from poor formation ability under the dry and humid status. 
       SUMMARY OF THE INVENTION 
       [0015]    Design objective: It aims to avoid defects in the background technologies, design a swiftly breakable and totally degradable non-woven spunlace and its fabrication methods and equipment. 
         [0016]    Design plan: In order to attain the above design objective: 1. The zigzagging flat viscose fiber has to receive pre-treatment design, which is the first technical features in the invention. It aims at the following objectives: The applied breakable and degradable non-woven spunlace is expected to reach the following technical index: water breaking property—It has to receive sealed pipe swing test for 50 times and is thus broken into total fiber. The weight is 30-100 gsm; humidity strength (MD): above 400 G/IN.; CD: above 200 G/IN. It has to not only realize the water breaking ability, but also enjoy necessary strength under the dry and humid status so that treatment of raw materials can guarantee the attainment of two contradictory technical index. Therefore, zigzagging flat 5-20 MM viscose fiber is laid in the feed mouth horizontally and fed into the cutting machine by conveyor; numerous incisions are formed on the surface or at the side of fiber by the high-speed shearing effect of flail knife to enlarge the fiber surface area, enhance the cohesive force of subsequent produced products and thus enable the application to realize the ability of swift water breaking and meet the strength demand under the dry and humid status. 2. The applied non-woven cloth is composed of 35-50% zigzagging flat viscose and 85-50% wood pulp, which is the second technical feature of the invention. It aims at the following objective: since the applied zigzagging flat viscose and wood pulp are pre-treated, the pre-treated fiber surface or side is thrown and cut into numerous incision structure which is easily entangled between fiber and incision in the spunlace treatment. It not only greatly upgrades the strength of continuous flaky non-woven cloth, but also brings convenience to swift breaking under the flushing effect. 3. The applied non-woven cloth does not need any adhesive and designed by natural degradable materials, which is the third technical feature of the invention. It aims at the following objective: since the raw materials of applied non-woven cloth is pre-treated, the pre-treatment result greatly enhances the entangled structure and surface of fibers; therefore, the applied breakable and degradable non-woven spunlace not only meets the requirement of swift water breaking, but also meets the strength demand for non-woven cloth under the dry and humid status without need for any adhesive materials. 4. The technical feature of this invention also includes indispensable design of fabrication methods of applied breakable and degradable non-woven spunlace. It aims at the following features: The applied breakable and degradable non-woven spunlace has to not only meet the requirement of swift water breaking, but also meet the strength demand for non-woven cloth under the dry and humid status without need for any adhesive materials; at the same time, it has to guarantee total degradation of broken non-woven cloth; five procedures listed for the fabrication methods of applied non-woven cloth are necessary methods to attain the above objective. They are closely linked with each other and necessary and irreplaceable-therefore, they constitute an inseparable technical plan. 5. The design of fabrication equipment of breakable and degradable non-woven spunlace is the fifth technical feature of the invention. It aims at the following features: In spite of existing equipment in the production line of applied breakable and degradable non-woven spunlace, it is the design objective to adopt the existing equipment to establish the above production line-it integrates the functions of existing equipment with applied equipment according to the design objective. It is inseparable and irreplaceable and thus constitutes a necessary part of the equipment. 6. Four corners of the clamping network are supported by the guide shaft and thus constitute a parallel rectangle structure, which is the sixth technical feature of the invention. It aims at the following objective: clamping network is collocated outside the microneedle spunlace head and in a clamping structure to the fleece between the support network of non-woven cloth. Under the effect of microneedle spunlace, the fleece does not suffer from serious displacement, evenness of fleece is guaranteed and fiber losses are reduced. 7. The design of water outlet aperture of microneedle spunlace head is 0.08 mm, which is the seventh technical feature of the invention. It aims at the following objective: The microneedle spunlace not only promotes mutual entanglement of fiber, but also makes a full use of friction force of slight incision on the viscose surface upon cutting process so that cohesive force is enhanced under dual effect and product with excellent humidity strength is produced without any chemical adhesive or hot melting fiber. 
         [0017]    Technical plan 1: It is a breakable and degradable non-woven spunlace composed of 35-50% zigzagging flat viscose fiber and 85-50% wood pulp. 
         [0018]    Technical plan 2: It means the fabrication methods of breakable and degradable non-woven spunlace: 
         [0019]    (1) 5-20 mm of 35-50% zigzagging flat viscose fiber is laid at the feed mouth horizontally and fed into the cutting machine by conveyor; numerous incisions are formed on the surface or at the side of fiber by the high-speed shearing effect of flail knife and deformed viscose fiber is obtained; 
         [0020]    (2) The deformed viscose fiber and wood pulp are conveyed to the cotton condenser from the feed mouth. The cotton condenser extracts the air produced in the transportation of raw materials; rotational cotton condenser freely fails raw materials to the mixer; 
         [0021]    (3) The mixer is composed of three groups of materials evening rollers; the materials are isolated in the middle and evened in three sections; the materials freely fallen into the mixer form a mixture of viscose fiber and wood pulp under the effect of mixer. Water is filled into the water inlet in the upper end of mixer so that materials in the mixer form adequately even work pulp; 
         [0022]    (4) The adequately even work pulp flows into the formation mouth and receive the common effect of negative pressure by non-woven cloth forming support network and suction box. Water is pumped away; raw fiber is reserved in the support network so that formed fabric sheet structure is produced; 
         [0023]    (5) The fabric is mobilized by the support network and input into the microneedle spunlace area; the fibers are mutually entangled by the microneedle spunlace head and water needle and sheet non-woven cloth is formed continuously. 
         [0024]    Technical plan 3: It is a production line of breakable and degradable non-woven spunlace, the terminal of conveyor is directly faced with the feed inlet of cutting machine; the discharge outlet of cutting machine is directly faced with the feed inlet of cotton condenser; the discharge outlet of cotton condenser is directly faced with the inlet of mixer; the outlet of mixer is directly faced with the forming support network of non-woven cloth; numerous microneedle spunlace heads in the forming support network of non-woven cloth are collocated with clamping network between the forming support network of non-woven cloth; the clamping network is sleeved in numerous microneedle spunlace heads. Numerous dehydration boxes are distributed under the forming support network of non-woven cloth. 
         [0025]    Compared with the background technology, the invention enjoys the following strengths: 1. It enjoys an excellent breaking property; 2. It realizes total degradation of non-woven cloth fiber upon breaking and avoids second environmental pollution; 3. Since the raw materials are pre-treated, the material features are greatly released and non-woven cloth enjoys an excellent formation strength under the dry and humid status; 4. The microneedle spunlace not only promotes mutual entanglement of fiber, but also makes a full use of friction force of slight incision on the viscose surface upon cutting process so that cohesive force is enhanced under dual effect and product with excellent humidity strength is produced without any chemical adhesive or hot melting fiber. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]      FIG. 1  is the structural schematic diagram of viscose in the breakable and degradable non-woven spunlace upon pre-treatment (throwing and cutting). 
           [0027]      FIG. 2  is the structural schematic diagram of viscose without pre-treatment (without throwing or cutting). 
           [0028]      FIG. 3  is the block diagram of fabrication methods of breakable and degradable non-woven spunlace. 
           [0029]      FIG. 4  is the partial structural schematic diagram of production line of breakable and degradable non-woven spunlace. 
           [0030]      FIG. 5  is the structural schematic diagram of clamping network. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0031]    Embodiment 1: refer to  FIGS. 1 and 2 . It is a breakable and degradable non-woven spunlace composed of 35-50% zigzagging flat viscose fiber  9  and 65-50% wood pulp. The said zigzagging flat viscose fiber  9  means the deformed viscose fiber  10  upon cutting process. The said zigzagging flat viscose fiber (deformed viscose fiber  10 ) is 5-20 mm in length. &gt;10 mm and ≦20 mm of the said 35-50% zigzagging flat viscose fiber (deformed viscose fiber  10 ) takes up 70-80%; ≧5 mm and ≦10 mm of the said 35-50% zigzagging flat viscose fiber (deformed viscose fiber  10 ) takes up 20-30%. The said wood pulp fiber is 1-5 mm in length. ≧1 mm and ≦3 mm of the said wood pulp fiber takes up 20-30%; &gt;3 mm and ≦5 mm of the said wood pulp fiber takes up 80-70%. The technical index of breakable and degradable non-woven spunlace is as follows: 
         [0032]    Water breakability—It receives sealed pipe swing test for 50 times and is thus broken into total fiber; gram weight: 30-100 gsm; humidity strength (MD): above 400 g/in.; CD: above 200 g/in. 
         [0033]    The clamping network is woven by polyester filament (diameter: 0.20-0.30 mm) horizontally and vertically; there are 50-65 meshes of clamping network (the quantity of polyester filament is 29 wires/cm). 
         [0034]    Embodiment 1-1: On the basis of embodiment 1, it is a breakable and degradable non-woven spunlace composed of 35% zigzagging flat viscose fiber 9 and 65% wood pulp. The said zigzagging flat viscose fiber  9  means the deformed viscose fiber  10  upon cutting process (please refer to cutting line in  FIG. 1 ). The said zigzagging flat viscose (deformed viscose  10 ) is 5-20 mm in length. &gt;10 mm and ≦20 mm of the above 35-50% zigzagging flat deformed viscose takes up 70-80%; ≧5 mm and ≦10 mm of the said 35-50% zigzagging flat deformed viscose takes up 20-30%. ≧1 mm and ≦3 mm of 65-50% wood pulp fiber takes up 20%; &gt;3 mm and ≦5 mm of the said wood pulp fiber takes up 80%. 
         [0035]    Embodiment 1-2: On the basis of embodiment 1, it is a breakable and degradable non-woven spunlace composed of 50% zigzagging flat viscose fiber 9 and 50% wood pulp. The said zigzagging flat viscose fiber  9  means the deformed viscose fiber  10  upon cutting process. &gt;10 mm and ≦20 mm of the said 35-50% zigzagging flat deformed viscose fiber takes up 70-80%; ≧5 mm and ≧10 mm of the said 35-50% zigzagging flat viscose fiber takes up 20-30%. ≧1 mm and ≦3 mm of 65-50% wood pulp fiber takes up 30%; &gt;3 mm and ≦5 mm of the said wood pulp fiber takes up 70%. 
         [0036]    Embodiment 1-3: On the basis of embodiment 1, it is a breakable and degradable non-woven spunlace composed of 40% zigzagging flat viscose fiber 9 and 60% wood pulp. The said zigzagging flat viscose fiber  9  means the deformed viscose fiber  10  upon cutting process. &gt;10 mm and ≦20 mm of the said 35-50% zigzagging flat deformed viscose takes up 70-80%; ≧5 mm and ≦10 mm of the said 35-50% zigzagging flat deformed viscose takes up 20-30%. ≧1 mm and ≦3 mm of 65-50% wood pulp fiber takes up 25%; &gt;3 mm and ≦5 mm of the said wood pulp fiber takes up 75%. 
         [0037]    Embodiment 2: it is a breakable and degradable non-woven spunlace composed of 35-50% zigzagging flat viscose fiber  9  and 65-50% wood pulp. The said zigzagging flat viscose fiber is 5-20 mm in length. 
         [0038]    Embodiment 2-1: On the basis of embodiment 1, it is a breakable and degradable non-woven spunlace composed of 35% zigzagging flat viscose fiber 9 and 65% wood pulp. The said zigzagging flat viscose fiber is 20 mm in length. 
         [0039]    Embodiment 2-2: It is a breakable and degradable non-woven spunlace composed of 50% zigzagging flat viscose fiber  9  and 50% wood pulp. The said zigzagging flat viscose fiber is 5 mm in length. 
         [0040]    Embodiment 2-3: It is a breakable and degradable non-woven spunlace composed of 40% zigzagging flat viscose fiber  9  and 60% wood pulp. The said zigzagging flat viscose fiber is 10 mm in length. 
         [0041]    Embodiment 3: Please refer to  FIG. 3-5 . It shows the fabrication methods of a breakable and degradable non-woven spunlace. 
         [0042]    (1) 5-20 mm of 35-50% zigzagging flat viscose fiber is laid at the feed mouth horizontally and fed into the cutting machine  1  by conveyor  8 ; numerous incisions are formed on the surface or at the side of fiber by the high-speed shearing effect of flail knife and deformed viscose fiber is obtained; 
         [0043]    (2) The deformed viscose fiber and wood pulp are conveyed to the cotton condenser  2  from the feed mouth. The cotton condenser  2  extracts the air produced in the transportation of raw materials; rotational cotton condenser  2  freely falls raw materials to the mixer  3 ; 
         [0044]    (3) The mixer  3  is composed of three groups of materials evening rollers; the materials are isolated in the middle and evened in three sections; the materials freely fallen into the mixer form a mixture of viscose and wood pulp under the effect of mixer. Water is filled into the water inlet in the upper end of mixer so that materials in the mixer form adequately even work pulp; 
         [0045]    (4) The adequately even work pulp flows into the formation mouth and receive the common effect of negative pressure by non-woven cloth forming support network  4  and suction box  7 . Water is pumped away; raw fiber is reserved in the support network so that formed fabric sheet structure is produced; 
         [0046]    (5) The fabric is mobilized by the support network and input into the microneedle spunlace area; the fibers are mutually entangled by the microneedle spunlace head and water needle and sheet non-woven cloth is formed continuously. The clamping network is collocated outside the microneedle spunlace head and in a clamping structure to the fleece between the support networks. Under the effect of microneedle spunlace, the fleece does not suffer from serious displacement, evenness of fleece is guaranteed and fiber losses are reduced. 
         [0047]    Embodiment 5: Please refer to  FIG 4 . It is a production line of breakable and degradable non-woven spunlace, the terminal of conveyor  8  is directly faced with the feed inlet of cutting machine  1 ; the discharge outlet of cutting machine  1  is directly faced with the feed inlet of cotton condenser  2 ; the discharge outlet of cotton condenser  2  is directly faced with the inlet of mixer  3 ; the outlet of mixer  3  is directly faced with the forming support network of non-woven cloth  4 ; numerous microneedle spunlace heads  5  in the forming support network of non-woven cloth  4  are collocated with clamping network  6  between the forming support network of non-woven cloth  4 ; the clamping network  6  is sleeved in numerous microneedle spunlace heads  5 . Numerous dehydration boxes  7  are distributed under the forming support network of non-woven cloth  4 . Three groups of materials evening rollers of the mixer  3  are distributed in equal angle; the mixing teeth are collocated in the materials roller. The mixer  3  is collocated with sprayer  12  and water inlet  13 . Four corners of the clamping network  6  constitute a parallel rectangle structure by the support of guide shaft. The water outlet aperture of microneedle spunlace head  5  is 0.08 mm. 
         [0048]    We have to understand that the said embodiments are simple and written description of the design idea of the invention instead of limitation to it. Any combination, increase or revision within the design idea is within the protective scope of invention.