Preparation and performance of high shrinkage polyester/polyamide 6 hollow pie-segmented spunbond needle-punching nonwovens
Objective In making nonwoven fabrics,the needling process can not make the two-component fibers split into ultrafine fibers.Because of this,the splitting effect of high shrinkage polyester(HSPET)/polyamide 6(PA6)hollow pie-segmented two-component spunbonded needle-punching nonwovens(hereinafter referred to as the HSPET/PA6 needle-punching nonwovens)is poor,resulting in the HSPET/PA6 needle-punching nonwovens can not give full play to offer the expected performance.It is necessary to identify ways of splitting the fibers in HSPET/PA6 needle-punching nonwovens,and to prepare hollow pie-segmented spunbond needle-punching nonwovens with high fiber splitting rates and excellent performance.Method The two-component spunbonded process was used to prepare HSPET/PA6 hollow pie-segmented spunbonded filaments,and HSPET/PA6 needle-punching nonwovens were formed by mesh lay-up and needle-punching reinforcement.The fiber splitting rates of nonwovens prepared by four different physical fiber splitting processes were compared to find out the optimal process.The softness,mechanical properties as well as air and moisture permeability of HSPET/PA6 needle-punching nonwovens were tested to analyze the effect of the optimal fiber splitting process on the properties of HSPET/PA6 needle-punching nonwovens.Results It was found that the fiber splitting rate of HSPET/PA6 needle-punching nonwovens was 18.9%,and dry heat treatment to the nowovens did not help the fiber splitting rate.However,the fiber splitting rate of HSPET/PA6 needle-punching nonwovens after hydrothermal treatment,ultrasonic treatment and rotary drum machine washing treatment were found to be 24.0%,32.6%and 75.5%,respectively.This indicates that the rotary drum washing can effectively improve the split rate of HSPET/PA6 needle-punching nonwovens,so that the two-component fibers split into ultrafine fibers.Subsequently,the changes in the properties of HSPET/PA6 needle-punching nonwovens before and after the fiber splitting treatment were investigated using the rotary drum machine washing treatment process.The fiber splitting rates of HSPET/PA6 needle-punching nonwovens were 57.4%,75.5%and 80.6%when the rotary drum washing treatment temperatures were ambient,60℃and 90℃,respectively.Considering the fiber splitting rate,production cost and environmental protection,60℃was selected as the appropriate treatment temperature for rotary drum machine washing.The effect of rotary drum washing treatment times on the performance of HSPET/PA6 needle-punching nonwovens was analyzed at the optimal rotary drum washing treatment temperature of 60℃.It was also found that the fiber splitting rate of HSPET/PA6 needle-punching nonwovens was gradually increased with the increase of rotary drum washing treatment time.The softness and mechanical properties of HSPET/PA6 needle-punching nonwovens was improved with the increase of the fiber splitting rate.However,along with the increase in the split fiber rate,the flexural aperture of HSPET/PA6 needle-punching nonwovens became smaller,resulting in a gradual decrease in the air permeability and moisture permeability of HSPET/PA6 needle-punching nonwovens.Conclusion The rotary drum washing process works well in splitting of two-component fibers during the needle punching process,and the process is simple and pollution-free without damaging the fibers.The rotary drum washing process provides a new direction for the splitting of pie-segmented two-component fibers and the preparation of nonwovens with a high fiber splitting rate.The needling process endows HSPET/PA6 needle-punching nonwovens a three-dimensional mesh structure,and the rotary drum washing treatment splits the two-component fibers into ultrafine fibers.The combination of the two processes gives HSPET/PA6 needle-punching nonwovens structural characteristics similar to those of natural leather,and provides the possibility that pie-segmented two-component spunbonded nonwovens can be widely used in the field of microfiber leather as a microfiber synthetic leather-based nonwovens.
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