The specific embodiment
As shown in Figure 1, a kind of printed polyester non-woven carpet plays flannelette blanket face 2, blanket face stamp 1 and blanket gum layer 3 by white nonwoven and consists of.White nonwoven carpet face 2 adopts the conventional polyester fiber, and manufacturing forms through the nonwoven production equipment.But white nonwoven carpet face 2 through being presented at after the high temperature fixation on white nonwoven carpet face 2, increases blanket face stamp 1 through the different design and color of ink-jet printing equipment spray printing.The stamp grey cloth of completing after spray printing carries out gluing, oven dry through modular system, increases blanket gum layer 3, finally forms printed polyester non-woven carpet.
As shown in Figure 2, terylene nonwoven carpet craft flow process is as follows:
By conventional white polyester staple fiber (basic specification is fineness 4-15dtex, length 51-75mm) feeding mixing willow is carried out preliminary shredding and hair, the terylene short fiber of different fineness and length is tentatively mixed; By 1 grade of shredding and the shredding of 2 grades of shredding two-stage openers, and spray simultaneously antistatic additive, make fiber block, coma from separating absent-mindedness, the fibrous raw material of different size obtains to mix uniformly; By cotton storage tank, fibrous raw material is further mixed; By the mixed fibroplastic fibrage of shredding is supplied with carding machine, make fibrous raw material obtain shredding more fully and evenly mix, mixed and disorderly cohesion mutually between fiber simultaneously, formation has the fibre web of certain cohesive force, and the grammes per square metre of fibre web is carried out Comprehensive Control by the speed of regulating cotton storage tank and carding machine; By lapping machine, fibre web that carding machine is exported is moved back and forth, with orderly interleaved mode laying, regulate in conjunction with the speed of output end curtain simultaneously, control the fibre web laying number of plies to reach the design surface density of product; By pre-needling machine, fibre web is carried out acupuncture, make entanglement obvolvent mutually between fiber, fibre web is reinforced, and between fiber, skid resistance becomes large, forms the pre-needling grey cloth with certain ultimate strength; By the needle-punching with napping machine, the pre-needling grey cloth is carried out high speed, the napping of highly dense acupuncture single face, thereby make the needle punched blanket of matte; Then needle punched blanket is carried out every check, after the assay was approved, carry out rolling by up-coiler, finally obtain the terylene nonwoven blanket grey cloth.
As shown in Figure 3, the technological process of terylene nonwoven carpet printing is as follows:
The terylene nonwoven blanket grey cloth is placed on the debatching device, and grey cloth obtains some tension after the traction of each roller of storage cloth holder, and it is neat and well spaced that cloth cover is straight, and can draw to the driving-belt of ink-jet decorating machine this moment with grey cloth is parallel; Meanwhile, carrying out soft water by ion exchange column processes, make soft water and thickener, dyestuff acquisition high speed dispersion mix or can directly disperse to mix with emulsification pump, the final evenly black slurry that forms be evacuated in 16 China ink bottles the China ink slurry stand-by with membrane pump afterwards again; Then according to the corresponding China ink bottle color of the color that draws a design, regulate the computer sprayed printed system, so that blanket grey cloth is carried out spray printing, ink ejection amount and jet speed are controlled by the adjustable pressure size, and the even spray printing of China ink slurry is on grey cloth; By tentering formula forming machine, the parallel traction of grey cloth after spray printing is entered baking oven (180-200 ℃ of maximum temperature scope, length 48m), dry in baking oven, color development and fixation process, the baking oven exit has cooling blower to carry out cooling processing to grey cloth, carries out simultaneously dry cleansing; Afterwards the stamp grey cloth is drawn to and puts cloth holder and carry out coolingly, and make cloth cover smooth by the roller drawing tension; At last the stamp grey cloth is carried out every check, carry out rolling by up-coiler subsequently, can pack product after the harvest volume and process or enter the processing of next process gluing.
(1) foundation of dye selection:
1. the material of carpet, use terylene short fiber, and is cheap, and buying is convenient;
2. the purposes of carpet, the carpet purposes is different, requires emphasis also different to the color fastness of dyestuff;
3. whether the color category of dyestuff is complete;
Whether 4. dye fixing speed, degree of fixation height and compatibility value be close all need consider, generally the painted disperse dyes of selecting of terylene are advisable.
(2) selection of thickener
Thickener refers to rise the macromolecular compound of thickening power in mill base, before adding mill base, generally it should be dispersed in water, and makes to have colloidal solution certain density, stiff.It is large many that the viscosity of its ratio of viscosities mill base is wanted.
Thickener mainly contains following effect:
1. mill base is carried out thickening;
2. the powder component of checking colors carries out the effect of decentralized medium and dilution;
3. the carrier between dyestuff and auxiliary agent;
4. promote colouring and fixation.
Thickener is required to be had: must overcome the imbibition phenomenon that the capillary effect due to pile causes, guarantee the decorative pattern clear-cut, this just requires print paste must have certain mobility, does not produce again imbibition simultaneously; Thickener also should have wetability, hygroscopicity and embrace water-based, and its concentration keeps stable after long storage time.
The principle that thickener is selected is as follows:
1. should first choose suitable dye type according to different carpet fiber materials, and then select corresponding thickener according to the characteristic of fiber and selected dyestuff;
2. should choose the high-purity synthetic thickening agent or through the sex change natural paste that process of refinement is crossed, guarantee that simultaneously nozzle is unobstructed;
3. thickener should have easy dispersion, easily become the characteristic of paste, and after becoming paste, viscosity keeps stablizing;
4. guarantee the thixotropic property of thickener, can satisfy simultaneously infiltration and the fineness requirement of carpet printing;
5. easy cleaning.
(3) preparation of standby slurry
General digital code spray-jet carpet knitter thickener used is the high-purity synthetic thickening agent, generally all needs thickener is mixed with former paste before the preparation mill base, as standby slurry.That is to say, namely add magma when stirring demineralized water, then fully stirring makes it to mix, thereby is mixed with more full-bodied magma, uses during in order to the preparation mill base.Standing a period of time afterwards, so that the abundant swelling of thickener, guarantee the stability of preparation mill base viscosity.
The detailed process of standby slurry preparation: namely add thickener in the time of agitating deionized water, continue afterwards to stir until slurry is even, the general stirring needs 15-30min consuming time (the concrete time decides according to the performance of variety classes thickener); After stirring, standing a period of time is so that thickener can be fully expanded.
What below introduce is by the prepared standby slurry viscosity of several middle thickeners:
160 * trme deposit slurry concentration 10g/l, the viscosity after complete swelling is the 12000cps left and right.
The concentration of 160conc deposit slurry is 16g/l, and the viscosity after complete swelling is 5000-6000cps.
The concentration of 5352 deposit slurries is 30g/l, and the viscosity after complete swelling is the 3000cps left and right.
The concentration of C T-D P deposit slurry is 16g/l, and the viscosity after complete swelling is 5000-6000cps.
The concentration of Texipo167-5055 deposit slurry is 10g/l, and the viscosity after complete swelling is 3000cps.
(4) composition of mill base and preparation
1. the part of mill base and effect thereof
Mill base generally is comprised of auxiliary agents such as thickener, dyestuff, bleeding agent, defoamer and anti-cremes, and the effect of main component is as follows.
A, bleeding agent:
Concentrator is permeated along knitting wool to the root direction, prevent slurry in the imbibition of blanket face, generally select low bubble bleeding agent to be advisable;
B, defoamer:
For preventing that effectively the auxiliary agent in concentrator from causing the spray printing difficulty in the stage of sizing mixing because producing a large amount of foams, can suitably add defoamer.Generally select the unabiding non-silicon defoamer of suds suppressing properties, in order to avoid the effect of the anti-creme of impact.
C, anti-creme:
When the wetting carpet surface fiber effects of concentrator not good, or carpet is when entering the relatively high steam box of humiture, due to humiture difference, makes steam in the carpet surface condensation, thereby cause dyestuff to ooze out from fiber surface, cause carpet surface " bloom " to occur.Anti-creme helps fiber wetting, can just form the little foam of thickness aspire to carpet surface in decatize, can prevent effectively that the dyestuff water that is condensed from taking out of, thereby reach the purpose of eliminating bloom.
2. the process for preparation of mill base
A, prior to adding the standby slurry of desired concn in a fixed container;
B, continue to add deionized water and other required auxiliary agents (as defoamer, bleeding agent etc.) (noting: all need dilute before chemical reagent adds) afterwards, stir;
C, at last dyestuff is fully dissolved, join after filtration (note: dyestuff must filter, because dyestuff contains impurity, some even can stop up shower nozzle) in slurry;
D, after being stirred to evenly, can tested viscosity, and be adjusted to according to actual needs suitable viscosity number.
(5) affect the factor of color coloured light:
The factor that affects color coloured light mainly comprises: dyestuff, carpet material, carpet background color, drying condition (being mainly time and temperature), mill base viscosity and pH value etc.;
1. dyestuff, when adding dyestuff, the dyestuff that adds each time, its purity and coloured light must be consistent respectively;
2. carpet material, unlike material carpet use that there is certain otherness in the color coloured light of gained after same dyestuff spray printing;
3. carpet background color, the carpet background color is pure white, but the overall color that other color presents after spray printing carpet all has impact in various degree;
4. drying condition needs suitably, and the length of time and the height of temperature all can exert an influence to the dyestuff color development;
5. mill base viscosity, general mill base viscosity is large, and color is full;
6. pH value 〉=7
(6) impact of every technic index on the spray printing effect
The spray printing effect of carpet is mainly considered from the following aspects: three aspects such as the saturation degree of color, permeance property and the 3rd look.
The concentration of saturation degree and dyestuff, colorant match etc. are relevant; Permeability comprises dyes material to the infiltration of carpet root direction and dyes material to two aspects of infiltration of blanket face direction, and it is relevant to bleeding agent, the moisture pick-up properties of blanket own etc.; The 3rd look relevant to color, viscosity, amount of thickener, pattern etc.
1. the factor that affects carpet spray printing effect mainly contains the following aspects:
The arranging density of a, carpet pile, height of naps and fluffy degree thereof;
B, mill base viscosity;
Characteristic and the consumption of c, thickener and dying auxiliary agent;
D, spray printing pressure;
E, spray printing height;
F, spray printing speed;
G, Steaming.
2. the adjusting of viscosity:
The principal element that affects viscosity has: the height of the self performance of carpet printing machine, the thickness of carpet, carpet pile, the fluffy degree of carpet pile and the arranging density of carpet pile etc.
The self performance of a, carpet printing machine requires viscosity to remain between 60-500cp, is preferably in below 450cp;
The thickness of b, carpet, thickness is different, and the requirement of the slurry viscosity of checking colors is also different.The general desired mill base viscosity of thin carpet is higher than thick type carpet;
The height of c, carpet pile, height of naps is higher, and the infiltration of dying material is more difficult, therefore the high required mill base that dyes material of carpet of fine hair should suitably hang down;
The fluffy degree of d, carpet pile, fluffy degree is good, dyes material and easily permeates; Otherwise, infiltration difficulty, this moment, its mill base viscosity can suitably reduce;
The arranging density of e, carpet pile, the fine hair arranging density is large, dyes material infiltration difficulty, and this moment, its mill base viscosity can suitably reduce;
Consider the scope that to determine mill base viscosity after above each factor, can use small model machine to draw a design and the vapour baking under reality, whether suitablely then evaluate the viscosity of initial judgement by the effect of final products.
3. affect the factor of infiltration:
The factor of impact infiltration mainly comprises: the arranging density of carpet pile, height of naps, mill base viscosity, bleeding agent consumption, spray printing pressure, spray printing speed, China ink amount.
A, fine hair arranging density are large, dye material infiltration difficulty, and can suitably increase the bleeding agent consumption this moment;
B, height of naps, highly larger, dye material infiltration difficulty, can suitably increase the bleeding agent consumption this moment;
C, mill base viscosity, in general, the material of dying that mill base viscosity is low is more easily permeated;
D, bleeding agent consumption are large, dye the material permeance property better, if but the consumption of bleeding agent is excessive, can make to dye material and spread to all directions infiltration, thus impact flower type, therefore should grasp the limit of bleeding agent consumption;
If after e increases the bleeding agent consumption, its permeance property is not still improved, may be that to cause participating in the amount of dye of carpet fiber reaction limited due to black quantity not sufficient, need to increase the China ink amount this moment;
F, spray printing pressure, spray printing pressure help greatly to dye the material infiltration;
G, spray printing speed are less, and the China ink amount increases, and dye material infiltration difficulty;
H, China ink amount, the China ink amount is large, dyes material infiltration difficulty;
Estimate bleeding agent consumption size and need consider above each factor, can at first carry out with small model machine the size that the concrete consumption of bleeding agent is determined in concrete experiment.
4. the China ink amount is definite:
The China ink amount of general carpet printing is the 300%-400% of carpet grammes per square metre, is namely 3-4 times of carpet grammes per square metre.Grammes per square metre refers to the weight (weight that mainly refers to carpet pile) of every square metre of carpet.
In general, dye material and be permeable to the carpet pile root or only carry out the part infiltration or only need painted the getting final product in carpet top layer, concrete condition is different, and China ink amount size is also different.
5. change the approach of China ink amount: spray printing pressure, spray printing speed, nozzle bore, slurry China ink viscosity.
A, spray printing pressure, each print cartridge are equipped with the corresponding button with regulation and control force value size separately, and the pressure of different colours dyestuff can there are differences, specifically depending on actual conditions (generally test definite by small model machine);
B, spray printing speed, spray printing speed is on the impact of China ink amount large (spray printing pressure is little on the impact of China ink amount than spray printing speed on the impact of China ink amount);
C, nozzle bore, if change spray printing pressure and spray printing speed still can satisfy the requirement of China ink amount not, this moment can be by changing the nozzle bore size to change black amount.
D, starch black viscosity, starching the large I of black viscosity directly affects the China ink amount, and viscosity is large, and whitewashing amount is little; Otherwise whitewashing amount is large.
(7) other points for attention
1. hardness of water must be less than 72ppm, and the hardness of soft water that use every day is consistent.
2. dyestuff must can be added in mill base after filtering.
3. accelerant ACE must be added in water and dilute, and must guard against directly to add in white slurry.
4. light slurry series, slurry amount and amount of dye are few, fixation is relatively very fast, the surface slurry be diluted move down before, dyestuff fixation is complete; For the dark colour mill base, if use different thickener consumption preparation same dark colour mill bases, and guarantee that its viscosity also can be adjusted to unanimously, final result shows, use the few formulated mill base of thickener consumption, when vapour dried by the fire, surperficial slurry easily was diluted downward infiltration, and easily to peripheral direction diffusion, thereby cause the color of fine hair tip shoal (being mainly because do not have due to enough thickener constraint dyestuffs); The mill base that uses thickener consumption polygamy system to form the problems referred to above can not occur, is mainly because amount of slurry is sufficient, so when vapour dry by the fire, the mill base mobile phase was to slowly, and mill base is that direction is permeated at the bottom of the blanket.
5. the color development time is definite, and generally lower than 10min, and in baking oven, temperature must keep uniformity.
6. for reducing error, every experiment condition of small model machine must be maximized physical condition during with large production of machinery be consistent.
7. during spray printing, follow spray printing principle from shallow to deep, if the position of two kinds of colors in pattern is more close, the material of dying with two kinds of colors is contained in respectively in relatively far apart two print cartridges and is advisable.
As shown in Figure 4, terylene nonwoven carpet typing coating technique flow process is as follows:
Grey cloth after the spray printing pattern has finished possesses certain tension force and intensity, can require to carry out gluing according to difference thus, is coated with flexible glue or ebonite.At first grey cloth is drawn to impregnator by the debatching device, and blanket faces down, blanket back glue.Secondly join glue and complete by mixer, the glue for preparing is evacuated to two of impregnators by foaming machine, and above pressure roller, can pass through adjusting two roller spacings, adjustment foaming density and speed of production this moment, and then control spread.Then the parallel traction of grey cloth after with gluing enters baking oven by tentering formula forming machine, in baking oven with drying adhesive.Again grey cloth is carried out every check, at last by the storage cloth holder draw, cooling, make the smooth rolling of grey cloth, be the terylene nonwoven Printing.